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Maintenance Manual
COPYRIGHT NOTICE
COPYRIGHT 2005 Mutoh Europe N.V. All rights reserved.
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 Mutohs 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,
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 article shown and the delivery of this document shall not constitute any right or license to
do so.
January 2005
Published: Mutoh Europe N.V., Archimedesstraat 13, B-8400 Oostende, BELGIUM
Important Notice
This product has been tested and found to comply with the limits for a Class A digital device, pursuant to Part
15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference
when the product is operated in a commercial environment.
This product generates, uses, and can radiate radio frequency energy and if not installed and used in
accordance with this manual, may cause harmful interference to radio communications. Operation of this
product in a residential area is likely to cause harmful interference in which case the user will be required to
correct the interference at his expense.
1.
Radio interfere
Product generates weak radio signals and may interfere with television reception and utilities. If a
product does interfere with radio or TV reception, try following:
2.
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.
Centronics and Bitronics are registered trademarks or product names of Centronics Data Computer
Corporation.
Other company and product names may be registered trademarks or product names.
No part of this product or publication may be reproduced, copied or transmitted in any form or by any means,
except for personal use, without the permission of MUTOH EUROPE N.V.
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.
MUTOH EUROPE N.V. shall not be liable for any damages or troubles resulting from the use of this
equipment or this manual.
TABLE OF CONTENTS
1. SAFETY INSTRUCTIONS............................................................................................................................. 9
1.1. INTRODUCTION ......................................................................................................................................... 9
1.2. WARNINGS, CAUTIONS AND NOTE.............................................................................................................. 9
1.3. IMPORTANT SAFETY INSTRUCTIONS ............................................................................................................ 9
1.4. WARNING LABELS ................................................................................................................................... 10
2. PRODUCT OVERVIEW................................................................................................................................11
2.1. INTRODUCTION ....................................................................................................................................... 11
2.2. PART NAMES AND FUNCTIONS .................................................................................................................. 11
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. Operation Panel Unwinder 100...................................................................................................................... 16
4. ADJUSTMENTS.......................................................................................................................................... 39
4.1. SENSOR (TENSION BAR) ADJUSTMENT UNWINDER/WINDER 100.................................................................. 39
(ONLY APPLICALBE FOR SYSTEMS MANUFACTURED BEFORE YEAR 2005)......................................................... 39
4.1.1. Understanding the principles of the sensors. ................................................................................................. 39
4.1.2. Adjust the sensors of the front tensioning bar................................................................................................ 40
4.1.3. Adjust the sensors of the rear tensioning bar ................................................................................................ 42
4.1.4. Sensor disc and adjustment direction ............................................................................................................ 45
4.1.5. Angle mark front tensioning system............................................................................................................... 46
4.1.6. Stop Sensor Position ..................................................................................................................................... 46
4.1.7. Start Sensor Position ..................................................................................................................................... 47
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.
Details
Must be followed carefully to avoid death or serious bodily injury.
Must be observed to avoid bodily injury (moderately or lightly) or damage to your
equipment.
Contains important information and useful tips on the operation of your printer.
Do not stand on or place heavy objects on the unit. Doing so may result in the unit tipping or
falling over and causing injury.
Do not attempt to plug in electrical plugs with wet hands. Doing so may result in electrical shock.
Do not use thinner, benzene, alcohol or other active agents. Doing so may result in damage or
paint peeling from the casing.
Be careful not to spill water inside the printer. Doing so may result in a short circuit.
Never open the covers fixed with screws. Doing so may result in electrical shock or a
malfunctioning in the unit.
When setting roll media, place it on top of a desk or other flat surface. Setting roll media with the
scroller standing up may damage them.
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.
10
2. PRODUCT OVERVIEW
2.1. INTRODUCTION
This chapter explains the features, part names and functions of the printer.
No.
1
Name
Roll-Off System
3
4
5
6
7
8
PCB Box
Rail Assembly
Motorized roll unit
Roll unit
Roll-off foot switch
Front Tension System
9
10
Roll-Up System
Operation Panel
Function
This is the device that sets the media when using roll media and feeds it to
the printing position.
Adjust the tension of the media between the roll-off system and the media
feed slot.
Contains the boards to control the unwinder / winder 100.
Carries the roll units.
Supports the roll media.
Supports the roll media.
This switch is used to roll-up or roll-off roll media of the unwinder 100.
Adjust the tension of the media between the paper guide and the roll-up
system.
This is the device that collects the media when using roll media.
This panel is used to set operational conditions, and the status of the product.
11
No.
A
B
Name
/
/
4
5
6
7
8
9
10
Backwards button
Forwards button
Winder 100 power ON
Manual
Winder 100 LED
Automatic
Backwards button
Forwards button
Power LED
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
OUT, otherwise select IN.
Toggle between Manual and Automatic mode.
LED lights up when pushing one of the buttons
Motor turns: LED flashes.
Motor is off : LED is out.
Outside printing
Inside printing
Roll-off unwinder
Roll-up unwinder
Roll-up unwinder
Roll-off unwinder
Power ON or OFF the winder 100.
LED lights up when pushing one of the buttons
Motor turns: LED flashes
Motor is off: LED is out.
Outside printing
Inside printing
Roll-off winder
Roll-off winder
Roll-up winder
Roll-up winder
Lightens up the system is powered ON.
12
2.2.3 Winder 30
No.
1
2
3
4
5
Name
Winder 30 motorized unit
Media sensor
Scroller receiver
Power switch
Operation Panel
Function
Winds and collects the printed roll media.
Detects the printed media.
Loads the scroller for the winding unit.
Turn the product ON and OFF.
This panel is used to set operational conditions, and the status of the product.
13
Name
AUTO switch
MANUAL switch
Function
Used to automatically wind the roll media.
Forward : When the media sensor detects the media, the
scroller automatically 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.
The winder system is manually operated.
Forward : The scroller rotates forward.
Backward : The scroller rotates backward.
Name
SENSOR lamp
Status
ON
Flashing
OFF
Function
The product is ON.
Waiting
An error has occurred.
The product is winding the media.
The product is OFF.
14
No.
1
Name
Roll-Off System
3
4
5
6
7
PCB Box
Rail Assembly
Motorized roll unit
Roll unit
Roll-off foot switch
Function
This is the device that sets the media when using roll media and
feeds it to the printing position.
Adjust the tension of the media between the roll-off system and
the media feed slot.
Contains the boards to control the unwinder 100.
Carries the roll units.
Supports the roll media.
Supports the roll media.
This switch is used to roll-up or roll-off roll media of the unwinder
100.
15
No.
Name
4
5
6
Backwards button
Forwards button
Power LED
Function
In case you loaded media with printed side on the outside select
OUT, otherwise select IN.
Toggle between Manual and Automatic mode.
LED lights up when pushing one of the buttons
Motor turns: LED flashes.
Motor is off : LED is out.
Outside printing
Inside printing
Roll-off unwinder
Roll-up unwinder
Roll-up unwinder
Roll-off unwinder
Lightens up once the system is powered ON
16
3. PARTS REPLACEMENT
3.1. INTRODUCTION
This chapter explains the procedures for replacing and removing maintenance parts.
Important :
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 :
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
Notes :
After replacing the parts, perform the adjustment of the unwinder / winder 100 as
described in the Users Guide.
17
Caution :
Be sure not to damage the cables nor the connectors.
Step 2 :
Step 3 :
18
Step 2 :
Step 3 :
Step 4 :
Step 5 :
Loosen the four screws fixing the operation panel PCB box.
Step 6 :
19
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.
20
Step 2 :
Step 3 :
Step 4 :
21
Step 5 :
Caution :
Be sure not to damage the cables nor the connectors.
Step 6 :
Step 7 :
22
Step 2 :
Step 3 :
Step 4 :
Step 5 :
23
Step 6 :
Step 7 :
Step 8 :
Step 2 :
24
Step 3 :
Step 4 :
Step 5 :
Step 6 :
25
1 = white
2 = black
3 = green/yellow (grounding)
Notes :
Please make sure to fix the cables together by using the cable clamp.
26
Step 1 :
Remove the five screws of the top cover of the take-up system and disconnect the power supply
cable.
No.
1
2
Step 2 :
Part
Top cover screws
Power supply cable
Remove the two screws of the switch board and disconnect the black flat cable connected to the
PCB board.
No.
1
Part
Switch board attaching screws
27
Step 3 :
No.
1
2
Part
Spacers
Screw
Step 4 :
Step 5 :
28
Step 2 :
Loosen the three screws fixing the cover of the tensioning sensor bracket.
Step 3 :
Step 4 :
Step 5 :
29
Step 6 :
Notes :
Repeat the steps above to remove the rear side sensor bracket.
30
Part
Number
Item
MK-51607
MK-51605
MK-51609
MK-51608
Front Stop
Sensor
Front Start
Sensor
Rear Stop
Sensor
Rear Start
Sensor
Sensor
covered
Sensor
registration
NO
YES
NO
YES
NO
YES
NO
YES
OFF
ON
OFF
ON
OFF
ON
OFF
ON
Description
Front motorized roll unit is turning constant speed.
The front motorized roll unit stops turning.
No speed change
Front motorized roll unit starts turning faster. Speed-up
Rear motorized roll unit is turning constant speed.
The rear motorized roll unit stops turning.
No speed change
Rear motorized roll unit starts turning faster. Speed-up
Notes :
Initial speed = very low (not visible). Feel the core cone to check movement.
After speeding up, return to initial speed by switching the active switch OFF and ON.
Caution :
Be sure not to damage the cables nor the connectors.
31
Step 2 :
Step 3 :
Step 4 :
Step 5 :
32
Step 2 :
Step 3 :
Step 4 :
Step 5 :
Step 6 :
Slide the new core cone into the motorized roll unit.
33
Step 2 :
Step 3 :
Step 4 :
1 = gear
Notes :
Step 5 :
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 6 :
34
Step 2 :
Step 3 :
Step 4 :
35
Remove the 4 hexagon socket head springs fixing the scroller R assembly.
1 = Scroller R assembly
Step 2 :
Step 3 :
Step 2 :
36
Step 3 :
1 = Pressure roller
3 = Roller 2
5 = E ring (E-4)
2 = Roller 1
4 = E ring (E-3)
Step 4 :
Step 5 :
Remove the 4 hexagon socket head springs fixing the scroller L assembly.
1 = Scroller L assembly
Step 2 :
Step 3 :
37
Step 2 :
Step 3 :
1 = Pressure roller
3 = E ring (E-3)
2 = Roller 1
4 = E ring (E-4)
Step 4 :
Step 5 :
38
4. ADJUSTMENTS
4.1. SENSOR (TENSION BAR) ADJUSTMENT UNWINDER/WINDER 100
(ONLY APPLICALBE FOR SYSTEMS MANUFACTURED BEFORE YEAR 2005)
Caution :
As from manufacturing date 2005, there is no need of adjusting the sensors because
of the new D-lock system.
A part of the adjustment is the adjustment of the sensors of the rear and front tensioning bar.
Please find below the procedures how to correctly adjust the sensors of the tensioning systems.
Notes :
For both the front and rear tensioning system :
By using two sensors, the unwinder / winder 100 will automatically adjust the media feed / winder speed to
the printing speed of the printer.
Stop Sensor
Open
Covered
Open
Start Sensor
Open
Open
Covered
Motor Action
Speed = constant
Stop
Accelerate
Notes :
Turning of the motor may not always be visible as the initial rotating speed is very
low. Feel the core cone or watch the Automatic LED to see if the motor is turning.
After acceleration, return to initial speed is possible by setting the Automatic switch to manual and back to
Automatic.
39
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. (Please refer to the section
Sensor disc and adjustment direction.)
All front tensioning bar angles are compared to the vertical plane.
First adjust the stop sensor, then the start sensor.
Make sure that the start sensor is not covered while adjusting the stop sensor.
Step 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 :
Step 4 :
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 front motor will stop turning.
Step 6 :
40
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. Please refer to the section Angle mark front
tensioning system.)
Step 3 :
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 front motor will start accelerating.
Step 5 :
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 front tensioning system has an angle of less than
approx. 12. (Front Automatic LED is OFF.)
should be open if the front tensioning system has an angle of more than approx.
12. (Front Automatic LED is blinking.)
The start sensor
should be open if the front tensioning system has an angle of less than approx.
25. (Front Automatic LED is blinking.)
should be covered if the front tensioning system has an angle of more than
approx. 25. (Front Automatic LED is ON.)
41
All rear tensioning bar angles are compared to the horizontal plane.
First adjust the stop sensor, then the start sensor.
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 :
Step 4 :
42
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.
Step 6 :
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 :
43
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.
Step 5 :
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 blinking.)
The start sensor
should be open if the rear tensioning system has an angle of less than approx.
30. (Rear Automatic LED is blinking.)
should be covered if the rear tensioning system has an angle of more than
approx. 30. (Rear Automatic LED is ON.)
44
45
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.
46
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.
47
A part of the adjustment is the adjustment of the sensors of the rear tensioning bar.
Please find below the procedures how to correctly adjust the sensors of the tensioning systems.
Notes :
For both the front and rear tensioning system :
By using two sensor, the unwinder will automatically adjust the media feed / winder speed to the printing
speed of the printer.
Stop Sensor
Open
Covered
Open
Start Sensor
Open
Open
Covered
Motor Action
Speed = constant
Stop
Accelerate
Notes :
Turning of the motor may not always be visible as the initial rotating speed is very
low. Feel the core cone or watch the Automatic LED to see if the motor is turning.
After acceleration, return to initial speed is possible by setting the Automatic switch to manual and back to
Automatic.
48
All rear tensioning bar angles are compared to the horizontal plane.
First adjust the stop sensor, then the start sensor.
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 :
Step 4 :
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.
Step 6 :
49
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 :
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.
Step 5 :
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 blinking.)
The start sensor
should be open if the rear tensioning system has an angle of less than approx.
30. (Rear Automatic LED is blinking.)
should be covered if the rear tensioning system has an angle of more than
approx. 30. (Rear Automatic LED is ON.)
50
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.
51
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.
52
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
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 :
Step 3 :
53
Step 4 :
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 :
Step 7 :
Slide the strip to the left side of the unit. Pull the strip so there is an equal tension.
Step 8 :
Step 9 :
54
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.
Step 12 : Repeat step 6 to step 12 until the lines overlaps each other.
55
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
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 :
Step 4 :
Step 5 :
Step 6 :
Standing at the front side of the unit, place the adjustment plate onto the large strip and slide it
against the pressure rollers.
56
Step 7 :
Step 8 :
Slide the strip to the left side of the unit. Pull the strip so there is an equal tension.
Step 9 :
57
Step 12 : Insert the adjustment brackets at the left or right side (depending on the deviation) of the winder
system below the rail assembly.
Step 15 : Perform the same adjustment procedure for the unwinder at the rear unit.
58
5. APPENDIX
5.1. INTRODUCTION
This chapter provides referential information such as service data and exploded views.
59
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
60
61
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
1
2
3
4
PART DESCRIPTION
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
QUANTITY
8
2
1
1
62
Step 2 :
Assemble the PCB-box, using 4 bolts M6x55 and 4 teeth washers M6..
ITEM
1
2
3
PART DESCRIPTION
DIN912 standard M6x55 ELVZ
Lock Washer Internal Teeth M6 ELVZ
PCB Box Assy Rollfeed Rockhopper II
QUANTITY
4
4
1
63
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.
ITEM
1
2
3
4
PART DESCRIPTION
Adjusting Foot Bracket Rollfeed Universal
Hex Flange Button Head M5x8 ELVZ
Levelling element M12
Steel bar Assy Rockhopper 87
QUANTITY
4 (*1)
16 (*1)
6 (*2)
2
64
(*1)
(*2)
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
1
2
3
4
PART DESCRIPTION
Clamp Lever M10x40
Sledge Left Assy Rollfeed Universal
Sledge Bracket Part 2 Rollfeed Universal
Sledge Right Assy Rollfeed Universal
QUANTITY
4
2
4
2
65
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 printer, use the most outer holes on the left side of the printer for assembling the left mounting bracket.
ITEM
1
2
3
4
PART DESCRIPTION
DIN 912 Standard M6x16 ELVZ
Lock Washer Internal Teeth M6 ELVZ
Mounting Bracket Left Assy Rollfeed Rockhopper II
Mounting Bracket Right Assy Rollfeed Rockhopper II
QUANTITY
8
1
1
1
66
ITEM
5
PART DESCRIPTION
Plain Washer DINI25-I A M6
QUANTITY
8
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
1
2
3
4
PART DESCRIPTION
Pan Head Screw
Shaft swingbar D-lock Rollfeed Rockhopper II
Swingbar Assy Rollfeed Rockhopper II
Swingbar Front Assy Rollfeed Rockhopper II
QUANTITY
4
2
1
1
67
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
1
2
PART DESCRIPTION
Hex Flange Buttonhead M5x8 ELVZ
Spacer PA D18 x d8.2 x H10
QUANTITY
8
8
68
69
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
1
2
3
4
PART DESCRIPTION
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
QUANTITY
8
2
1
1
70
Step 2 :
Assemble the PCB-box, using 4 bolts M6x55 and 4 teeth washers M6..
ITEM
1
2
3
PART DESCRIPTION
DIN912 standard M6x55 ELVZ
Lock Washer Internal Teeth M6 ELVZ
PCB Box Assy Rollfeed Rockhopper II
QUANTITY
4
4
1
71
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.
ITEM
1
2
3
4
PART DESCRIPTION
Adjusting Foot Bracket Rollfeed Universal
Hex Flange Button Head M5x8 ELVZ
Levelling element M12
Steel bar Assy Rockhopper 87
QUANTITY
4 (*1)
16 (*1)
6 (*2)
2
72
(*1)
(*2)
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
1
2
3
4
PART DESCRIPTION
Clamp Lever M10x40
Sledge Left Assy Rollfeed Universal
Sledge Bracket Part 2 Rollfeed Universal
Sledge Right Assy Rollfeed Universal
QUANTITY
4
2
4
2
73
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 printer, use the most outer holes on the left side of the printer for assembling the left mounting bracket.
ITEM
1
2
3
4
PART DESCRIPTION
DIN 912 Standard M6x16 ELVZ
Lock Washer Internal Teeth M6 ELVZ
Mounting Bracket Left Assy Rollfeed Rockhopper II
Mounting Bracket Right Assy Rollfeed Rockhopper II
QUANTITY
8
1
1
1
74
ITEM
5
PART DESCRIPTION
Plain Washer DINI25-I A M6
QUANTITY
8
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. 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
1
2
PART DESCRIPTION
Sensor Lip Assy Rollfeed Rockhopper II
Shaft tensioning system Rollfeed
Rockhopper II
QUANTITY
4
4
75
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
1
2
3
4
PART DESCRIPTION
Lock Washer External Teeth M5 ELVZ
Pan Head Screw M4x10
Rear tensioning system assy Rollfeed Rockhopper II 87
Front tensioning system assy Rollfeed Rockhopper II 87
QUANTITY
4
4
1
1
76
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
1
2
3
4
PART DESCRIPTION
Foot switch KF2 IS/IS
Hex Flange Button Head M5x8 ELVZ
Spacer PA D18xd8.2xH10
Waste bottle roll feed RH RJ-8164
QUANTITY
1
4
4
1
77
ITEM
1
2
3
4
PART DESCRIPTION
Countersunk Screw M4x10 Nickel Coated
Hex Flange Button head M4x10 ELVZ
Interface Plate Rollfeed RHII 87
Media Sensor Assembly Winder 30
QUANTITY
4
4
1
1
78
ITEM
5
6
7
8
PART DESCRIPTION
Pan Head Screw M4x10
Scroller Support Assy Rockhopper II 50 and 64
Scroller Support Assy Rockhopper II 87
Take-up Motor Box assy RJ-8000
QUANTITY
6
1
1
2
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
79
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
1
2
3
4
PART DESCRIPTION
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
QUANTITY
8
2
1
1
80
Step 3 :
Reinstall the waste bottle on the place described below.
For a Falcon II
For a Rockhopper II
81
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
1
2
3
PART DESCRIPTION
Hex Flange Button head M5x8 ELVZ
PCB Box Assy Rollfeed Rockhopper II
PCB Box Bracket Rollfeed Rockhopper II
QUANTITY
6
1
1
82
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.
ITEM
1
2
3
4
PART DESCRIPTION
Adjusting Foot Bracket Rollfeed Universal
Hex Flange Button Head M5x8 ELVZ
Levelling element M12
Steel bar Assy Rockhopper 87
QUANTITY
2 (*1)
8 (*1)
3 (*2)
1
83
(*1)
(*2)
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
1
2
3
4
PART DESCRIPTION
Clamp Lever M10x40
Sledge Left Assy Rollfeed Universal
Sledge Bracket Part 2 Rollfeed Universal
Sledge Right Assy Rollfeed Universal
QUANTITY
2
1
2
1
84
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 printer, use the most outer holes on the left side of the printer for assembling the left mounting bracket.
ITEM
1
2
3
4
PART DESCRIPTION
DIN 912 Standard M6x16 ELVZ
Lock Washer Internal Teeth M6 ELVZ
Mounting Bracket Left Assy Rollfeed Rockhopper II
Mounting Bracket Right Assy Rollfeed Rockhopper II
QUANTITY
8
1
1
1
85
ITEM
5
PART DESCRIPTION
Plain Washer DINI25-I A M6
QUANTITY
8
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
1
2
3
PART DESCRIPTION
Pan Head Screw M4x10
Shaft tensioning bar D-lock Rollfeed
Tensioning bar Rollfeed
QUANTITY
2
1
1
86
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
1
2
3
PART DESCRIPTION
Foot switch KF2 1S/1S
Hex flange Buttonhead M5x8 ELVZ
Spacer PA D18 x d8.2 x H10
QUANTITY
1
4
4
87
ITEM
1
2
3
4
PART DESCRIPTION
Countersunk Screw M4x10 Nickel Coated
Hex Flange Button head M4x10 ELVZ
Interface Plate Rollfeed RHII 87
Media Sensor Assembly Winder 30
QUANTITY
4
4
1
1
88
ITEM
5
6
7
8
PART DESCRIPTION
Pan Head Screw M4x10
Scroller Support Assy Rockhopper II 50 and 64
Scroller Support Assy Rockhopper II 87
Take-up Motor Box assy RJ-8000
QUANTITY
6
1
1
2
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
89
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
1
2
3
4
PART DESCRIPTION
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
QUANTITY
8
2
1
1
90
Step 3 :
Reinstall the waste bottle on the place described below.
For a Falcon II
For a Rockhopper II
91
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
1
2
3
PART DESCRIPTION
Hex Flange Button head M5x8 ELVZ
PCB Box Assy Rollfeed Rockhopper II
PCB Box Bracket Rollfeed Rockhopper II
QUANTITY
6
1
1
92
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.
ITEM
1
2
3
4
PART DESCRIPTION
Adjusting Foot Bracket Rollfeed Universal
Hex Flange Button Head M5x8 ELVZ
Levelling element M12
Steel bar Assy Rockhopper 87
QUANTITY
2 (*1)
8 (*1)
3 (*2)
1
93
(*1)
(*2)
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
1
2
3
4
PART DESCRIPTION
Clamp Lever M10x40
Sledge Left Assy Rollfeed Universal
Sledge Bracket Part 2 Rollfeed Universal
Sledge Right Assy Rollfeed Universal
QUANTITY
2
1
2
1
94
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 printer, use the most outer holes on the left side of the printer for assembling the left mounting bracket.
ITEM
1
2
3
4
PART DESCRIPTION
DIN 912 Standard M6x16 ELVZ
Lock Washer Internal Teeth M6 ELVZ
Mounting Bracket Left Assy Rollfeed Rockhopper II
Mounting Bracket Right Assy Rollfeed Rockhopper II
QUANTITY
8
1
1
1
95
ITEM
5
PART DESCRIPTION
Plain Washer DINI25-I A M6
QUANTITY
8
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.
Assemble the cable between the operating panel and the PCB-box.
ITEM
1
2
PART DESCRIPTION
Sensor Lip Assy Rollfeed Rockhopper II
Shaft tensioning system Rollfeed Rockhopper II
QUANTITY
2
2
96
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
1
2
3
PART DESCRIPTION
Lock Washer External Teeth M5 ELVZ
Pan Head Screw M4x10
Rear tensioning system assy Rollfeed Rockhopper II 87
QUANTITY
2
2
1
97
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
1
2
3
4
PART DESCRIPTION
Foot switch KF2 IS/IS
Hex Flange Button Head M5x8 ELVZ
Spacer PA D18xd8.2xH10
Waste bottle roll feed RH RJ-8164
QUANTITY
1
4
4
1
98
5.3.3 Unwinder 30
Scroller support L
99
Scroller support R
100
101