You look at the finished job, and your heart sinks.
The lines are skewed, the cut is incomplete, and another expensive sheet of vinyl is headed for the trash can.
Your Summa D60, once a reliable workhorse, is now a source of frustration and wasted material. Before you call a costly technician, you should know that the culprit is very often a small, simple-to-fix component: the pinch rollers.
These critical parts are responsible for gripping and guiding your media, but they don’t last forever.
This is the most comprehensive guide you will find for a complete pinch roller replacement on your Summa D60.
We will walk you through identifying the problem, gathering the right tools, and performing the replacement with the precision of a factory-trained technician. This is a specialized equipment repair, but the logic is straightforward.
For more general troubleshooting, see our Ultimate Guide to DIY Vehicle Repair & Diagnostics.
1 The Problem vs. The Solution: Worn vs. New Pinch Rollers
| Feature | Worn-Out Pinch Rollers | New Genuine Summa Pinch Rollers |
|---|---|---|
| Vinyl Grip | Slipping and inconsistent tracking | Precise and firm grip on media |
| Cut Accuracy | Skewed lines, incomplete cuts, ruined jobs | Perfect, repeatable cuts every time |
| Material Waste | High, due to repeated failed jobs | Minimal, maximizing your profitability |
| Machine Noise | Squeaking or grinding sounds | Quiet, smooth operation |
| Your Confidence | Low, uncertainty with every job | High, reliable results you can count on |
2 What are Pinch Rollers and Why Do They Wear Out?
Think of the pinch rollers on your Summa D60 as the machine’s hands.
Their one and only job is to apply firm, even downward pressure, pinning the vinyl against the drive drum’s sleeves. This grip is what allows the cutter to precisely move media back and forth along the X-axis, ensuring your designs are cut exactly as you intended.
Without this perfect traction, accuracy is impossible.
Like the tires on a car, these rollers are high-wear components.
Over time, the constant pressure and friction cause the rubber to harden, crack, or develop flat spots. This is especially true if the rollers are left in the “down” position for extended periods when the machine isn’t in use, as it permanently deforms the rubber.
Dust and debris from your shop environment can also accumulate on the rollers, reducing their grip.
3 Symptoms of Worn-Out Pinch Rollers on a Summa D60
The signs of failing pinch rollers are often mistaken for more complex mechanical or electronic problems.
Before you start troubleshooting software or replacing expensive boards, check for these tell-tale symptoms. The most common sign is your vinyl slipping or tracking poorly during a cut, leading to misaligned or incomplete designs.
You might also notice that the cut depth is inconsistent or that the machine gives an axis error when the material tension gets too high.
A visual inspection can also reveal a lot.
Look for shiny, glazed surfaces on the rollers, cracks in the rubber, or a visible “flat spot” where the roller has been compressed. In some cases, you might even hear a squeaking or grinding noise as the hardened roller struggles to move with the media.
4 How Bad Rollers Lead to Poor Vinyl Tracking and Wasted Material
That tiny flat spot or slight loss of grip on a pinch roller has massive consequences.
As the drive drum spins, the roller fails to hold the vinyl securely. Even a microscopic slip with each rotation will compound over the length of a job. The vinyl will begin to “walk” or skew to one side.
The machine’s sensors don’t know the material has shifted, so the cutter head continues along its programmed path.
The result is a design that veers off-course, ruining the cut and forcing you to start over. This directly translates into wasted time, wasted vinyl, and lost profit.
5 The Tools You’ll Need for the Replacement
You don’t need a full technician’s toolkit for this job.
The beauty of this Summa D60 maintenance task is its simplicity. Here’s a short checklist of what to have on hand:
A small flathead screwdriver: For prying off the retaining clip.
A new set of genuine Summa Pinch Rollers: Part number 395-401 is what you’ll typically need.
A soft, lint-free cloth.
Isopropyl alcohol: For cleaning the shaft and contact points.
6 A Step-by-Step Guide to Replacing Summa D60 Pinch Rollers
Here is the clearest, most straightforward process for a successful pinch roller replacement.
Follow these steps exactly, and your machine will be back to peak performance in no time.
7 Step 1: Powering Down and Gaining Safe Access to the Assembly
Safety first.
Before you touch any components, power down your Summa D60 and unplug it from the wall outlet. This eliminates any risk of electrical shock or accidental machine movement.
Raise the pinch roller lever on the right side of the machine to lift the rollers off the drive drum. This will give you the slack you need to work.
8 Step 2: Removing the Old Pinch Roller Assembly
With the roller assembly raised, gently slide it along the shaft to a position where you have clear access.
Look closely at the end of the small metal shaft that the rubber roller spins on. You will see a small C-clip or E-clip in a groove.
Take your small flathead screwdriver and carefully pry this clip off the shaft. Be gentle and try not to send the clip flying across the room.
Once the clip is removed, the shaft will easily slide out of the pinch roller block.
You can now remove the entire old, worn-out pinch roller. It’s a good idea to have a small container handy to keep the shaft and clip together so they don’t get lost.
9 Step 3: Cleaning the Shaft and Contact Points
With the old roller out of the way, take this opportunity to perform some basic cleaning.
Dampen your lint-free cloth with a small amount of isopropyl alcohol and wipe down the shaft you just removed. Also, clean the inside of the pinch roller block where the shaft sits.
Removing any built-up dust and grime will ensure the new parts move freely and last longer.
10 Step 4: Installing the New Pinch Rollers Correctly
Take your new pinch roller and slide it into position in the pinch roller block.
Then, re-insert the clean shaft through the block and the new roller. Make sure it is seated correctly.
The final, and most crucial, step is to reinstall the retaining clip. Position the clip back onto the groove at the end of the shaft and push it down firmly until it clicks into place.
When I first picked up the genuine Summa replacement roller, part number 395-401, the first thing I noticed was the uniform texture and pliability of the rubber compared to the hardened, shiny one I just removed.
In my field test, the new roller gripped the vinyl firmly without leaving marks. The fit on the shaft was snug, with no play, which is critical for preventing tracking errors.
11 Step 5: Reassembly and Performing a Test Cut
With the new roller securely installed, you’re ready to test your work.
Plug the machine back in and power it on. Load a scrap piece of vinyl, ensuring the newly installed pinch roller is positioned correctly over one of the drive sleeves.
Lower the pinch roller lever and perform a test cut. Watch the material closely to ensure it tracks straight and true.
12 Where to Buy Genuine Summa D60 Replacement Pinch Rollers
You wouldn’t put cheap, off-brand tires on a performance car, and you shouldn’t use non-OEM parts on your Summa plotter.
For a perfect fit and guaranteed performance, always use genuine Summa replacement parts. The correct kit for this job, which typically includes two rollers and clips, is part number 395-401.
You can purchase these directly from authorized resellers who specialize in sign-making equipment repair.
If new pinch rollers don’t solve your tracking issue, the problem might be electronic.
Learn about diagnosing a mainboard in our guide to eagle-1 slide motherboard replacement.
13 Tips for Extending the Life of Your New Pinch Rollers
Now that you’ve restored your cutter’s performance, let’s keep it that way.
The single most important thing you can do is to always leave the pinch rollers in the “up” position when the cutter is not in use. This prevents the rubber from developing the flat spots that cause tracking issues.
Regular cleaning also goes a long way.
Periodically wipe down the rollers and the drive drum with a soft cloth to prevent residue buildup.
Sometimes a mechanical issue can present like an electrical one, similar to how fuel problems can mimic a bad CDI. See our guide on a 2001 DS 650 that runs for 2 seconds to understand diagnostic paths.
FAQ: Summa Pinch Roller Replacement
How often should you replace Summa pinch rollers?
There is no fixed schedule for replacement.
You should replace them when you notice the symptoms of wear, such as vinyl slipping, poor tracking, or visible damage to the rubber like cracks or flat spots.
Why is my vinyl slipping in my Summa cutter?
The most common cause of slipping vinyl is worn-out or dirty pinch rollers.
When the rubber loses its grip, it can no longer hold the media securely against the drive drum, causing tracking errors.
Can I use non-OEM pinch rollers on a Summa D60?
While you might find third-party options, it is highly recommended to use genuine Summa parts.
OEM rollers are manufactured to exact specifications for diameter and rubber composition, ensuring optimal grip and longevity. Using off-brand parts can lead to continued tracking issues.
How do I clean my pinch rollers to improve grip?
For routine cleaning, use a soft, lint-free cloth lightly dampened with isopropyl alcohol to wipe the roller surface.
For more stubborn residue, you can use the tacky side of a piece of scrap vinyl. Lower the rollers onto the sticky side of the vinyl and manually move the vinyl back and forth to pull off the grime.
