MUTOH Kona 760 Service Manual
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MUTOH Kona 760 Service Manual

For machine versions: a1, a2, a3 and a4
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Service
Manual
For machine versions:
A1, A2, A3 and A4
Based on firmware version 3.0.0
& Mutoh CutServer version 3.0.0
For service technicians only!

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Table of Contents
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Summary of Contents for MUTOH Kona 760

  • Page 1 Service Manual For machine versions: A1, A2, A3 and A4 Based on firmware version 3.0.0 & Mutoh CutServer version 3.0.0 For service technicians only!
  • Page 3 Copyright notice COPYRIGHT © 27/4/10 Mutoh Europe nv All rights reserved. Mutoh Europe nv reserves the right to modify the information contained in this manual at any time without prior notice. This document may not be reproduced by any means, in whole or in part, without written permission of the copyright owner.
  • Page 4 Restore back-up parameters using the Mutoh CUTserver page 99  If there are no back-up parameters available, you have to do the  following: Calibrate X and Y distance accuracy using the Mutoh CUTserver page 102  Perform Y-Z measurement (diagnostics) page 93 ...

  • Page 5: Table Of Contents

    Service manual Kona cutting plotter Table of contents Chapter 1 Regulations and safety information ... . . 9 Warnings, cautions and notes ......10 Compliance with the following regulations .
  • Page 6 Service manual Kona cutting plotter Chapter 3 Part replacement ......25 Cover removal ........27 Side covers .
  • Page 7 ......99  Mutoh CutServer tests ......100 Tracking test .
  • Page 8 Service manual Kona cutting plotter Chapter 5 Diagnostics mode ......105 Introduction ........106 How to start up in diagnostics mode 1 and 2 .

  • Page 9: Chapter 1  Regulations And Safety Information

    Service manual Kona cutting plotter Regulations and safety information Chapter 1  Regulations and  safety information Warnings, cautions and notes ....... . . 10 Compliance with the following regulations .

  • Page 10: Warnings, Cautions And Notes

    Service manual Kona cutting plotter Regulations and safety information Warnings, cautions and notes Safety terms in this manual and the contents of warning labels attached to the cutter are categorized into the following three types, depending on the degree of risk (or the scale of accident).

  • Page 11: Important Notes

    Service manual Kona cutting plotter Regulations and safety information Your product is designed and manufactured with high-quality materials and components, which can be recycled and reused. When this crossed-out wheeled bin submenu is attached to a product, it means the product is covered by the European Directive 2002/96/EC - WEEE regulation.

  • Page 12: Safety Labels

    Be sure not to stare in the laser mounted on the cutting head. Serial number label providing you the following information: Serial number  Unit name  Power supply requirements  Regularisations  Class A product  Address Mutoh Europe n.v.  AP-74380 - Revision 1.1...

  • Page 13: Chapter 2 Product Overview

    Service manual Kona cutting plotter Product overview Chapter 2 Product overview Dimensions machine ......... 14 Installation environment requirements .

  • Page 14: Dimensions Machine

    Service manual Kona cutting plotter Product overview Dimensions machine Kona 760 Kona 1400 Kona 1650 Width 1200 mm / 47,2” 1850 mm / 72,8” 2090 mm / 82.3” Depth 260 mm / 10,2” 490 mm / 19,3” 490 mm / 19,3”...

  • Page 15: Room Conditions

    Service manual Kona cutting plotter Product overview 2.2.3 Room conditions Please protect your cutter from moisture, dust, draughts and direct sunlight (to prevent  possible media detection and epos readout issues). It is best to keep your machine away from open windows and air-conditioners. See to it that there is an adequate space around the cutter so that ventilation is not ...

  • Page 16: Part Names And Functions

    Service manual Kona cutting plotter Product overview Part names and functions N° Description Extended description Pressure rollers To push the media against the grit rollers A guiding platform with vacuum fans to transport Media guide the media as flat as possible during cutting Provides a reliable cutting surface and minimizes Cutting mat damage to the knife tip...

  • Page 17: Overview Operation Panel

    Service manual Kona cutting plotter Product overview Overview operation panel 2.4.1 Main menu N° Description Extended description Settings button Open the settings menu 1/4 Actions button Open the actions menu 1/2 This icon will appear as from the moment the Kona is connected via USB USB indication to the computer AND the correct drivers are installed.

  • Page 18: Settings Or Actions Menu

    Service manual Kona cutting plotter Product overview 2.4.2 Settings or actions menu N° Description Extended description Home button Go back to the home menu (the menu shown above) Settings button Open the settings menu 1/4 Actions button Open the actions menu 1/2 Back / cancel button Go back to the previous menu in the hierarchy Previous button...

  • Page 19: Settings Or Actions Menu

    Service manual Kona cutting plotter Product overview 2.4.3 Adjust value menu N° Description Extended description Home button Go back to the home menu (the menu shown above) Settings button Open the settings menu 1/4 Actions button Open the actions menu 1/2 Go back to the previous menu in the hierarchy and/or cancel Back / cancel button the settings change...

  • Page 20: Menu Overview

    Service manual Kona cutting plotter Product overview Menu overview 2.5.1 User mode Main menu Sub menus BOLD = default value Settings 1/4 Velocity Tool down 1 - 60 -100 cm/s Tool up 1 - 100 cm/s Offset Offset 0.1 - 0.5 - 1 mm Test Force Force...

  • Page 21: Diagnostics Mode 1 And 2

    Service manual Kona cutting plotter Product overview Main menu Sub menus BOLD = default value Settings 3/4 Epos Alignment Automatic Manual Language English Greek Polski Portugues Italiano Espanol Deutsch Francais Nederlands Protocol Emulation HPGL2 HPGL MHGL2 MHGL VS/ZF/AS Accept Ignore Resolution 0.010 mm 0.025 mm...
  • Page 22 Service manual Kona cutting plotter Product overview Main menu Sub menus BOLD = default value Actions 1/2 Jogging Origin Cut Through Trim poster Length Width Contour Cut Multi frame Single scan Repeat mode Single frame Single scan Repeat mode Manual Length Width Direction...

  • Page 23: Diagnostics Mode 1 And 2

    Service manual Kona cutting plotter Product overview 2.5.2 Diagnostics mode 1 and 2 Refer to Diagnostics mode on page 105 for further details. Availability Diagnostics 1 Diagnostics 2 Connection Encoder PWM test User Defaults Machine Accuracy YZ profile Measure Tool Force Verify Laser Actuators...

  • Page 24: Machine Version

    The version label of the machine can be found behind the right side cover. Refer to Cover removal > Side covers on page 28 Note The list of differences between the versions can be requested at our service department (service@mutoh.eu). AP-74380 - Revision 1.1...

  • Page 25: Chapter 3 Part Replacement

    Service manual Kona cutting plotter Part replacement Chapter 3 Part replacement Important Before replacing parts, be sure to take the following precautionary measures:  Power OFF the cutter  Unplug the power cable  Disconnect all other cables  Only the parts described in this chapter may be replaced and are available as a ...
  • Page 26 Service manual Kona cutting plotter Part replacement Grit shaft ........... 53 Exploded view .

  • Page 27: Cover Removal

    Service manual Kona cutting plotter Part replacement Cover removal N° Description Get access to the following parts Removal procedure Belt return pulley assy  Left cover page 28 Grit shaft drive pulley and belt  Penhead assembly  Head FFC (flex flat cable) ...

  • Page 28: Side Covers

    Service manual Kona cutting plotter Part replacement 3.1.1 Side covers Tools necessary P2 screwdriver  Removal procedure Remove the 2 screws fixing the side cover. Step 1: Hook off the side covers. Step 2: Reassembling notes When reinstalling the cover, hook it over the positioning points of the side frame. AP-74380 - Revision 1.1...

  • Page 29: Y-Rail Cover

    Service manual Kona cutting plotter Part replacement 3.1.2 Y-rail cover Tools necessary P2 screwdriver  Removal procedure Remove on of the side covers first. Step 1: Refer to Cover removal > Side covers on page 28 Loosen the 4 screws fixing the Y-rail cover. Step 2: Remove the Y-rail cover.

  • Page 30: Penhead Cover

    Service manual Kona cutting plotter Part replacement 3.1.3 Penhead cover Tools necessary P2 screwdriver  Removal procedure Remove side covers and Y-rail cover first Step 1: Refer to Cover removal > Y-rail cover on page 29 Remove the 3 screws fixing the penhead cover. Step 2: Remove the penhead cover.

  • Page 31: Front Platen

    Service manual Kona cutting plotter Part replacement 3.1.4 Front platen Tools necessary P2 screwdriver  Removal procedure Remove the side covers, Y-rail cover and penhead cover. Step 1: Refer to Cover removal > on page 27 Remove the 3 screws fixing the front platen. Step 2: Loosen the screw at the left and right side pushing down the front platen.

  • Page 32: Rear Platen

    Service manual Kona cutting plotter Part replacement 3.1.5 Rear platen Tools necessary P2 screwdriver  Removal procedure Remove the following covers first: Step 1: Side covers  Refer to Cover removal > Side covers on page 28 Y-rail cover  Refer to Cover removal >...

  • Page 33: X-Motor And Drive Belt

    Service manual Kona cutting plotter Part replacement X-motor and drive belt Tools necessary P2 screwdriver  Replacement procedure Follow the procedure below to replace the X-motor and/or drive belt. Remove the following covers first: Step 1: Left cover  Refer to Cover removal >...
  • Page 34 Service manual Kona cutting plotter Part replacement Replace the motor and cable. Step 4: Remove the grounding bracket. Step 5: Replace the drive belt. Step 6: Adjustments necessary After replacing this part, it is necessary to make the following adjustment. N°...

  • Page 35: Y-Motor Assembly

    Service manual Kona cutting plotter Part replacement Y-motor assembly 3.3.1 Exploded view rear front front rear N° Description Replacement procedure Y-motor page 36 Y-drive pulley page 38 Speed reduction belt page 39 Y-return pulley page 39 AP-74380 - Revision 1.1...

  • Page 36: Y-Motor

    Service manual Kona cutting plotter Part replacement 3.3.2 Y-motor Tools necessary P2 screwdriver  Replacement procedure Follow the procedure below to replace the Y-motor. Remove the following covers first: Step 1: Right cover  Refer to Cover removal > Side covers on page 28 Front platen ...
  • Page 37 Service manual Kona cutting plotter Part replacement Disconnect the following cables: Step 3: From motor to mainboard  From motor to lever up/down sensor  Put the lever in the down position. Step 4: Gently tilt out and replace the Y-motor. Step 5: Adjustments necessary After replacing this part, it is necessary to make the following adjustment.

  • Page 38: Y-Drive Pulley And Speed Reduction Belt

    Service manual Kona cutting plotter Part replacement 3.3.3 Y-drive pulley and speed reduction belt Tools necessary P1 and P2 screwdriver  Replacement procedure Follow the procedure below to replace the Y-drive pulley and speed reduction belt. Remove all covers except the front and rear platen Step 1: Refer to Cover removal on page 27...

  • Page 39: Y-Return Pulley

    Service manual Kona cutting plotter Part replacement 3.3.4 Y-return pulley Tools necessary P2 screwdriver  Replacement procedure Follow the procedure below to replace the Y-return pulley. Remove the following covers first: Step 1: Left cover  Refer to Cover removal > Side covers on page 28 Y-rail cover ...

  • Page 40: Penhead Assembly

    Service manual Kona cutting plotter Part replacement Penhead assembly 3.4.1 Exploded view N° Description Replacement procedure Penhead FFC (flexible flat cable) page 41 Penhead PCB page 75 Penhead drive belt page 47 Sheet-off mechanism page 49 EPOS sensor block page 50 Y-origin flex PCB page 52 AP-74380 - Revision 1.1...

  • Page 41: Penhead Ffc (Flexible Flat Cable)

    Service manual Kona cutting plotter Part replacement 3.4.2 Penhead FFC (flexible flat cable) Tools necessary P2 screwdriver  Snap-off blade  Replacement procedure Follow the procedure below to replace the penhead FFC. Remove the following covers first: Step 1: Right cover ...
  • Page 42 Service manual Kona cutting plotter Part replacement Carefully loosen the flatcable guider (only for Kona 1400 and 1650). Be careful not Step 4: to bend the guider and to cut in the flatcable! Loosen the 2 brackets fixing the flatcable at the right side of the cutter. Step 5: Unplug the flatcable from the mainboard and replace it.
  • Page 43 Service manual Kona cutting plotter Part replacement Reassembling notes Move the penhead to the far left of the machine and press it against the pen until the Step 1: sheet-off knife is pushed out completely. Mount the flatcable to the penhead PCB and fix the flatcable bracket. Step 2: Start guiding the flatcable in the gutter until you reach the middle (where no double Step 3:...

  • Page 44: Penhead Assembly

    Service manual Kona cutting plotter Part replacement 3.4.3 Penhead assembly Tools necessary P2 screwdriver  Hexagon wrench 5,5 mm  Hexagon key 2,5 mm  Replacement procedure Follow the procedure below to remove the penhead assembly. Remove the following covers first: Step 1: Remove the following covers first Step 2:...
  • Page 45 Service manual Kona cutting plotter Part replacement Remove the screw fixing the penhead to the drive belt. Step 6: Remove the screw on top of the penhead. Step 7: Remove the leaf spring. Step 8: Remove penhead assembly by tilting it of the Y-rail. Step 9: AP-74380 - Revision 1.1...
  • Page 46 Service manual Kona cutting plotter Part replacement Adjustments necessary After replacing/removing this part, it is necessary to make the following adjustment. N° Description Link EPOS calibration EPOS calibration on page 103 YZ profile YZ measurement on page 93 Reassembling notes Pay attention to the order of the installation of the leaf spring, washer and screw. Install the leaf spring.

  • Page 47: Penhead Drive Belt

    Service manual Kona cutting plotter Part replacement 3.4.4 Penhead drive belt Tools necessary P2 screwdriver  Hexagon wrench 5,5 mm  Hexagon key 2,5 mm  Replacement procedure Follow the procedures below to replace the penhead drive belt. Remove the following covers first Step 1: Side covers ...
  • Page 48 Service manual Kona cutting plotter Part replacement Remove the 4 screws of the drive belt connection plate. Step 5: Replace the penhead drive belt. Step 6: Adjustments necessary After replacing this part, it is necessary to make the following adjustment. N°...

  • Page 49: Sheet-Off Mechanism

    Service manual Kona cutting plotter Part replacement 3.4.5 Sheet-off mechanism Tools necessary P2 screwdriver  Replacement procedure Remove the 2 screws fixing the sheet-off mechanism. Step 1: Replace the sheet-off mechanism. Step 2: Refer to the User’s Guide to know how to replace the sheet-off blade only. Adjustments necessary After replacing this part, it is necessary to make the following adjustment.

  • Page 50: Epos Sensor Block

    Service manual Kona cutting plotter Part replacement 3.4.6 EPOS sensor block Tools necessary P2 screwdriver  Replacement procedure Follow the procedure below to replace the EPOS sensor block. Remove the following covers first: Step 1: Remove the following covers first Step 2: Side covers ...
  • Page 51 Service manual Kona cutting plotter Part replacement Remove the screw fixing the EPOS sensor block. Step 4: Replace the EPOS sensor block. Step 5: Adjustments necessary After replacing this part, it is necessary to make the following adjustment. N° Description Link EPOS calibration EPOS calibration on page 103...

  • Page 52: Y-Origin Flex Pcb

    Service manual Kona cutting plotter Part replacement 3.4.7 Y-origin flex PCB Tools necessary P2 screwdriver  Hexagon wrench 5,5 mm  Hexagon key 2,5 mm  Replacement procedure Follow the procedure below to replace the Y-origin flex PCB. Remove the following covers first Step 1: Side covers ...

  • Page 53: Grit Shaft

    Service manual Kona cutting plotter Part replacement Grit shaft 3.5.1 Exploded view N° Description Replacement procedure Grit shaft page 54 Grit shaft bearings page 54 Grit shaft support rolls page 58 AP-74380 - Revision 1.1...

  • Page 54: Grit Shaft And Support Rollers

    Service manual Kona cutting plotter Part replacement 3.5.2 Grit shaft and support rollers Tools necessary Paper sheets (A5 - A4)  Tape  P2 screwdriver  Hexagon key 1,5 mm  Loctite 641  Hammer  Replacement procedure Follow the procedure below to replace the grit shaft and support rollers. Remove all the covers of the cutter Step 1: Refer to...
  • Page 55 Service manual Kona cutting plotter Part replacement Install a piece of paper between the grit shaft and each support roll assembly to Step 5: avoid damaging them when pulling out the shaft later on. Loosen the 2 setscrews of the speed reduction pulley. Step 6: Remove the speed reduction pulley and white spacer.
  • Page 56 Service manual Kona cutting plotter Part replacement Hammer out the grit shaft from the right side of the machine until the bearing at the Step 9: left comes out. Remove the grit shaft assembly. Step 10: Remove the 2 screws fixing the right bearing of the grit roll shaft. Step 11: Remove the bearing at the right side of the cutter.
  • Page 57 Service manual Kona cutting plotter Part replacement Reassembling notes The grit shaft support rolls can be mounted in two ways (as shown below). Be sure to install them correctly. With the large collar of the bearing facing the screw. When replacing the grit shaft, you will have to order a kit including the following items: Grit shaft ...
  • Page 58 Service manual Kona cutting plotter Part replacement Install a bearing and push it as far as possible. Step 4: Remove the spoiled glue. Step 5: Install the grit shaft from left to right. Be careful not to damage the grit sections when Step 6: moving it through the hole in the left end plate.

  • Page 59: Pressure Roller Assembly

    Service manual Kona cutting plotter Part replacement Pressure roller assembly 3.6.1 Exploded view N° Description Replacement procedure Pressure roller assembly page 61 Pressure roller page 60 AP-74380 - Revision 1.1...

  • Page 60: Pressure Roller

    Service manual Kona cutting plotter Part replacement 3.6.2 Pressure roller Tools necessary Small screwdriver  Replacement procedure Follow the procedure below to replace the pressure roller. Be sure that the pressure rollers raised. Step 1: Push on the pressure roller shaft (left and right) until the pressure roller clicks out of Step 2: its base.

  • Page 61: Pressure Roller Assembly

    Service manual Kona cutting plotter Part replacement 3.6.3 Pressure roller assembly Tools necessary P1 and P2 screwdriver  Hexagon wrench 5,5 mm  Hexagon key 2,5 mm  Replacement procedure Follow the procedure below to replace the pressure roller assembly. Remove all the covers of the cutter Step 1: Refer to...
  • Page 62 Service manual Kona cutting plotter Part replacement Remove the hexagon pressure roller shaft as follows: Step 4: Put the pressure rollers in the up position.  Remove the shaft stop and spacer (at the left side) by loosening the set screw. ...
  • Page 63 Service manual Kona cutting plotter Part replacement Remove Y-rail as follows: Step 5: Support the Y-rail so it can not fall when disassembling it.  Loosen the grounding strip avoiding static electricity on top of the Y-rail.  Remove the 4 screws fixing the Y-rail at both sides. ...
  • Page 64 Service manual Kona cutting plotter Part replacement Mark the position of the end stop. Step 6: Loosen the screw fixing the end stop and slide out the stop. Step 7: Slide out the pressure roller assembly and replace it. Step 8: AP-74380 - Revision 1.1...
  • Page 65 Service manual Kona cutting plotter Part replacement Reassembling notes Be sure to push the Y-rail to the front against the positioning points on the side frames before fixing the rail. Be sure to guide and tighten the flatcables in the same way as shown on the picture below: Adjustments necessary After replacing this part, it is necessary to make the following adjustment.

  • Page 66: Cutting Mat

    Service manual Kona cutting plotter Part replacement Cutting mat Tools necessary Isopropanol  Replacement procedure Please follow the procedure below to replace the cutting mat. Remove the following covers first Step 1: Side covers  Y-rail cover  Penhead cover ...

  • Page 67: Electronics

    Mutoh CutServer and PC  Replacement procedure Follow the procedure below to replace the mainboard. Store the current parameters using the Mutoh CutServer. Step 1: Refer to Parameters > Backup parameters of machine on page 98 Remove the following covers first:...
  • Page 68 Service manual Kona cutting plotter Part replacement Remove the 2 screws fixing the mainboard. (only for machine versions A1 and A2) Step 4: Refer to Machine version on page 24 Push in all studs with a set of pliers, remove the mainboard and replace it. Step 5: Reassembling notes Follow the procedure below to replace the flatcables correctly.
  • Page 69 If there are no parameters available, either perform the additional adjustments mentioned below or contact our service department (service@mutoh.eu) X - Y distance accuracy Mutoh CutServer tests on page 102  Y - Z measurement Mechanical adjustments on page 93  EPOS calibration EPOS calibration on page 103...
  • Page 70 Service manual Kona cutting plotter Part replacement Board diagnostics AP-74380 - Revision 1.1...
  • Page 71 Service manual Kona cutting plotter Part replacement Connector overview Connector and function J1 (+48V) (fans) J2 (rev A mainboards) or J12 (rev C mainboards) (to headboard) J3 (to LCD) J7 (X-motor and encoder) J8 (Y-motor and encoder) J9 (Power supply) J10 (Sensors) J1 (+48V) (fans) Pin name...
  • Page 72 Service manual Kona cutting plotter Part replacement J7 (X-motor and encoder) Pin name ENC_A ENC_B J8 (Y-motor and encoder) Pin name ECN_A ENC_B J9 (Power supply) Pin name +48V +48V J10 (Sensors) Pin name +5V0 nRear Paper +5V0 nFront Paper +5V0 nMid Paper AP-74380 - Revision 1.1...
  • Page 73 Service manual Kona cutting plotter Part replacement Pin name +5V0 nLever LED summary Function LD1 G +48 V LD2 R Error LED 2 LD3 R Error LED 1 LD4 R Error LED 3 LD5 R Error LED 4 LD6 Y Alive LD14 R X motor (V-)

  • Page 74: And Y Motor Fuse

    Service manual Kona cutting plotter Part replacement 3.8.2 X and Y motor fuse Tools necessary P2 screwdriver  Pair of tweezers  Replacement procedure Follow the procedure below to replace the X or Y motor fuse Remove the following covers first Step 1: Side covers ...

  • Page 75: Penhead Pcb

    Service manual Kona cutting plotter Part replacement 3.8.3 Penhead PCB Tools necessary P2 screwdriver  Hexagon wrench 5,5 mm  Replacement procedure Follow the procedure below to replace the penhead PCB. Remove the following covers first: Step 1: Side covers ...
  • Page 76 Service manual Kona cutting plotter Part replacement Board diagnostics Connector overview Connector and function J1 (to mainboard) J2 is not used J3 (EPOS) J4 (Y-origin) J5 (PenHead) J1 (to mainboard) Pin name COIL+ COIL- DO_48V_OUT2+ DO_48V_OUT2- DI_5V0_IN5 DO_5V_OUT3 +5V0 AP-74380 - Revision 1.1...
  • Page 77 Service manual Kona cutting plotter Part replacement Pin name AI_5V0_EPOS1 AI_5V0_EPOS2 J3 (EPOS) Pin name +5V0 AI_5V0_EPOS2 AI_5V0_EPOS1 DO_5V_OUT3 J4 (Y-origin) Pin name nY-Origin J5 (PenHead) Pin name +5V0 COIL+ COIL- AP-74380 - Revision 1.1...

  • Page 78: Power Supply

    Service manual Kona cutting plotter Part replacement 3.8.4 Power supply Important Be sure to remove the power cable before servicing the power supply!  Tools necessary P2 screwdriver  Replacement procedure Follow the procedure below to replace the power supply. Remove the following covers first: Step 1: Side covers...
  • Page 79 Service manual Kona cutting plotter Part replacement Depending on the machine version, a protective cover has been installed above the Step 4: power supply. Remove it before replacing the power supply. Remove the 4 screws fixing the power supply. Step 5: Replace the power supply.

  • Page 80: Touchscreen

    Service manual Kona cutting plotter Part replacement 3.8.5 Touchscreen Tools necessary P2 screwdriver  Replacement procedure Follow the procedure to replace the touchscreen. Remove the following covers first: Step 1: Right cover  Refer to Cover removal > Side covers on page 28 Y-rail cover ...

  • Page 81: Sensors

    Service manual Kona cutting plotter Part replacement 3.8.6 Sensors Tools necessary P2 screwdriver  Pressure roller lever sensor Follow the procedure below to replace the lever sensor. Remove the right cover. Step 1: Refer to Cover removal > Side covers on page 28 Disconnect the sensor cable.
  • Page 82 Service manual Kona cutting plotter Part replacement Front and middle paper sensor Follow the procedure below to replace the front and middle paper sensor. Remove the front platen. Step 1: Refer to Cover removal > Front platen on page 31 Disconnect the sensor cable.

  • Page 83: Vacuum Fans

    Service manual Kona cutting plotter Part replacement 3.8.7 Vacuum fans Tools necessary P2 screwdriver  New cutting mat  Replacement procedure Follow the procedure below to replace the vacuum fans. Remove the following covers first: Step 1: Side covers  Y-rail cover ...
  • Page 84 Service manual Kona cutting plotter Part replacement AP-74380 - Revision 1.1...

  • Page 85: Adjustments And Calibrations

    Mutoh CutServer tests ........

  • Page 86: Mechanical Adjustments

    Service manual Kona cutting plotter Adjustments and calibrations Mechanical adjustments 4.1.1 X drive belt tension After replacing the following parts: Part Link X motor and drive belt replacement X-motor and drive belt on page 33 Grit shaft replacement Grit shaft on page 53 Adjustment procedure Follow the procedure below to adjust the tension of the X drive belt.

  • Page 87: Y Drive Belt Tension

    Service manual Kona cutting plotter Adjustments and calibrations 4.1.2 Y drive belt tension After replacing the following parts: Part Link Y motor replacement Y-motor on page 36 Y-drive pulley and speed reduction belt Y-drive pulley and speed reduction belt on page 38 Pressure roller assembly replacement Pressure roller assembly on page 61 Adjustment procedure...

  • Page 88: Penhead Drive Belt Tension

    Service manual Kona cutting plotter Adjustments and calibrations 4.1.3 Penhead drive belt tension After replacing the following parts: Part Link Y-drive pulley and speed reduction belt Y-drive pulley and speed reduction belt on page 38 Y return pulley replacement Y-return pulley on page 39 Penhead drive belt replacement Penhead drive belt on page 47 Pressure roller assembly replacement...
  • Page 89 The tension depends of the size of the Kona. For Kona 760 the value should be 200 g ± 5 g.  For Kona 1400 the value should be 130 g ± 5 g.

  • Page 90: Pressure Roller Pressure

    Service manual Kona cutting plotter Adjustments and calibrations 4.1.4 Pressure roller pressure After replacing the following parts: Part Link Pressure roller assembly replacement Pressure roller assembly on page 61 Adjustment procedure Follow the procedure below to adjust the pressure of the pressure roller assembly. Make sure that the pressure rollers are raised.

  • Page 91: Sheeting-Off Knife Position

    Service manual Kona cutting plotter Adjustments and calibrations Be sure to fasten the nuts to each other and verify the pressure once more. Step 8: 4.1.5 Sheeting-off knife position After replacing the following parts: Part Link Pressure roller assembly replacement Pressure roller assembly on page 61 Penhead assembly replacement Penhead assembly on page 44...
  • Page 92 Service manual Kona cutting plotter Adjustments and calibrations Adjust the sheet-off knife height so that the metal bracket of the spring-wheel Step 3: mechanism does not touch the upper or lower part of the extrusion. Check this over the complete width of the machine. This way the wheel will control the play of the front platen.

  • Page 93: Yz Measurement

    Service manual Kona cutting plotter Adjustments and calibrations 4.1.6 YZ measurement After replacing the following parts: Part Link Cutting mat replacement Cutting mat on page 66 Vacuum fan replacement Vacuum fans on page 83 Penhead replacement Penhead assembly on page 44 Adjustment procedure Refer to Menu overview >...

  • Page 94: Software And Drivers

    Service manual Kona cutting plotter Adjustments and calibrations Software and drivers 4.2.1 Download latest software and drivers Always download the latest firmware from Mutoh’s firmware download FTP. Link ftp://firmware@ftp.mutoh.be/firmware_download User account firmware Password download 4.2.2 Firmware installation Make a connection between the Kona and your computer using a USB cable. Be...
  • Page 95 Service manual Kona cutting plotter Adjustments and calibrations The machine will restart automatically. Step 12: Note It might be possible that the machine does not restart because of an update  failure or a power down during the update sequence. The 4 error LEDs on the mainboard will start blinking.

  • Page 96: How To Uninstall The Usb Drivers

    Service manual Kona cutting plotter Adjustments and calibrations 4.2.3 How to uninstall the USB drivers Make sure your Kona is powered ON and connected to the PC. Step 1: In the Device manager you will find your device Step 2: Virtual serial port ...

  • Page 97: How To Install The Usb Drivers

    Next. Choose Install from a list or specific location and press next to continue. Step 5: Browse to the folder with USB drivers you have downloaded from Mutoh’s FTP. Step 6: Windows will search the hardware.

  • Page 98: Parameters

    Another dialogue window will appear when the backup has been succeeded Step 4: successfully. You can find the backup file in a specified folder "Backup" of the Mutoh CutServer. Step 5: You can browse to the folder on either of these two ways: Installation folder of the Mutoh CutServer...

  • Page 99: Restore Parameters Of Machine

    ON and connected to the PC via USB  the USB drivers are installed.  the Mutoh CutServer has been launched and a connection has been established  Right-click on the opened connection and choose to restore backup to a machine... Step 2: An overview of the available files will be displayed.

  • Page 100: Mutoh Cutserver Tests

    When you encounter or believe that the cutting plotter has a tracking problem, you can verify that with this tracking test. This test is only accessible via the Mutoh CutServer. Please be sure to perform the test within following conditions: Temperature between 5 °C and 30 °C...
  • Page 101 When establishing a deformation to the left or right, check the following things and perform the test once again. If none of these help, please contact our Mutoh Service Department. Be sure that you are testing within the conditions summarized in the beginning of the ...

  • Page 102: Xy-Distance Accuracy Test

    Please follow the procedure below to make the test: Launch Mutoh’s CUTserver. Step 1: Be sure that the cutter is connected with the Mutoh CUTserver. Step 2: Select which test to perform. Step 3: Select the appropriate COM-port and double-click.

  • Page 103: Epos Calibration

    Service manual Kona cutting plotter Adjustments and calibrations EPOS calibration This test will fine-tune the position of the cutting knife compared to the EPOS laser. This test can be done manually and automatically. It is recommended however, to let the Kona adjust the values automatically.
  • Page 104 Service manual Kona cutting plotter Adjustments and calibrations Automatic alignment Manual alignment Weed out the square and press OK Weed out the squares and press OK Step 8: The cutter will automatically measure The EPOS laser will be activated and Step 9: the bottom and right side of the box, to will move to the approximate centre of...

  • Page 105: Diagnostics Mode

    Service manual Kona cutting plotter Diagnostics mode Chapter 5 Diagnostics mode Introduction..........106 How to start up in diagnostics mode 1 and 2 .

  • Page 106: Introduction

    Service manual Kona cutting plotter Diagnostics mode Introduction Diagnostics is a powerful tool in the firmware made for the authorized Mutoh technician to control/check a lot of settings, features, parts… Diagnostics can be used as well when the machine starts-up correctly (diagnostics 1), but also when the cutting plotter does not pass the initialization procedure (diagnostics 2).

  • Page 107: Diagnostics 2

    Service manual Kona cutting plotter Diagnostics mode 5.2.2 Diagnostics 2 Note Note that this diagnostics mode has some restrictions. Not all diagnostic  menus are displayed compared with the diagnostics mode entering after complete start-up and initialization. Power ON the machine at the side. Step 1: Press on the touchscreen in the lower right corner during start-up to enter Step 2:...

  • Page 108: Menu Overview

    Service manual Kona cutting plotter Diagnostics mode Menu overview Availability Link Diagnostics 1 Diagnostics 2 Connection Connection on page 109 Encoder Encoder on page 110 PWM test PWM test on page 111 User Defaults Defaults on page 112 Machine Accuracy Accuracy on page 113 YZ profile YZ profile on page 114 Measure Tool Force...

  • Page 109: Connection

    Service manual Kona cutting plotter Diagnostics mode 5.3.1 Connection Via this menu it is possible to check the polarity of the X and Y motor. Go to diagnostics mode 1 Step 1: Refer to Diagnostics 1 on page 106 Be sure that the pressure rollers are raised. Step 2: Press on the connection button Step 3:...

  • Page 110: Encoder

    Service manual Kona cutting plotter Diagnostics mode 5.3.2 Encoder When you are in doubt that the X, Y or Z encoder still functions, verify this as follows: Go to diagnostics mode 1 or 2 Step 1: Refer to Diagnostics 1 on page 106 Refer to Diagnostics 2 on page 107 Press on the encoder button...

  • Page 111: Pwm Test

    Service manual Kona cutting plotter Diagnostics mode 5.3.3 PWM test When you are in doubt that the X, Y or Z motor still functions correctly, verify this as follows: Go to diagnostics mode 1 or 2 Step 1: Refer to Diagnostics 1 on page 106 Refer to Diagnostics 2 on page 107...

  • Page 112: Defaults

     Quality setting  Cut through setting  Machine defaults: The settings for which a calibration is necessary (from an authorized  Mutoh technician) XY accuracy calibration  Refer to XY-distance accuracy test on page 102 EPOS calibration  Refer to EPOS calibration on page 103...

  • Page 113: Accuracy

    The machine will reboot and all settings will be reset. Step 5: 5.3.5 Accuracy In this menu it is only possible to read out the values sent by the Mutoh CutServer to the Kona. Refer to Mutoh CutServer tests > XY-distance accuracy test on page 102...

  • Page 114: Yz Profile

    Unload media and be sure that the lever is up. Step 3: Move the pressure rollers to the following position: Step 4: Kona 760 - on grit roller 1 and 6  Kona 1400 - on grit roller 1 and 5 and 11 ...

  • Page 115: Tool Force

    Service manual Kona cutting plotter Diagnostics mode 5.3.7 Tool Force This feature is meant for production purposes only. You will notice that this value will be reset when restoring the factory defaults. However, this is not an issue since the default settings are very close to the actual values.

  • Page 116: Sensors

    Service manual Kona cutting plotter Diagnostics mode 5.3.9 Sensors When you are in doubt of the correct functioning of the sensors, verify it as follows: Go to diagnostics mode 1 or 2. Step 1: Refer to Diagnostics 1 on page 106 Refer to Diagnostics 2 on page 107 Press on the Sensors button.

  • Page 117: Aging

    Service manual Kona cutting plotter Diagnostics mode 5.3.10 Aging This feature let you repeat predefined movements of the following routines: Cutting  Sheeting off  Cutting through  For each routine, some predefined patterns are included. Use the default settings or adjust them as you prefer.
  • Page 118 Service manual Kona cutting plotter Diagnostics mode Velocity  Acceleration  Force  Tool Up or Down  Start the aging test using the settings and pattern displayed  After making the settings and pressing the play button, the cutter will cut the set Step 5: amount of test patterns.

  • Page 119: Screen

    Service manual Kona cutting plotter Diagnostics mode 5.3.11 Screen After replacing the touchscreen or when establishing irregularities, recalibrating the screen or setting the tension (VCM value) might help. Go to diagnostics mode 1. Step 1: Refer to Diagnostics 1 on page 106 Press on the Screen button.
  • Page 120 Service manual Kona cutting plotter Diagnostics mode AP-74380 - Revision 1.1...

  • Page 121: Chapter 6 Troubleshooting

    Service manual Kona cutting plotter Troubleshooting Chapter 6 Troubleshooting Important Before changing parts or start troubleshooting, it is strongly advised to check  the firmware version. If the cutter is not up-to-date. Try to install the latest firmware version first and check again if Refer to Software and drivers > Firmware installation on page 94 Troubleshooting when no error is displayed.

  • Page 122: Troubleshooting When No Error Is Displayed

    Service manual Kona cutting plotter Troubleshooting Troubleshooting when no error is displayed 6.1.1 General troubleshooting Power switch is turned on but the cutting plotter does not operate: N° Possible solution Link Connect power cable. Check wall outlet. Check if LED LD1G on the mainboard is lit green. Mainboard >...
  • Page 123 Connect the USB cable. ‐ Check if the Kona displays the ready message in the mainscreen. ‐ Try to send tests from the Mutoh CutServer. Reboot cutting plotter Reinstall USB drivers Parts of the design are not properly cut: Cutting quality related problem: N°...
  • Page 124 Slow down cutting speed. Perform offset calibration. Perform quality tests from Mutoh CutServer. Mutoh CutServer tests > Tracking test on page 100 Check parameter JOB FOCUS in user menu. Select ACCURACY instead of SPEED. Check X&Y belt tensions.
  • Page 125 Slow down cutting speed Slow down "TOOL UP SPEED" in user menu Check parameter JOB FOCUS in user menu. Select ACCURACY instead of SPEED. Perform tracking tests via the Mutoh CutServer. Tracking test on page 100 Check pressure roll pressure. Mechanical adjustments on page 90 Replace grit shaft Grit shaft and support rollers on page 54...

  • Page 126: Recoverable Error Messages With No Error Id Number

    During a cutting, measuring or other sequence, it might be possible that one of the below errors occur. Please find a list below with all the possible errors which can be solved yourself, without any need of an intervention by an authorized Mutoh technician.
  • Page 127 EPOS problem: No It might be possible that the reference Select the correct file in the Mutoh CutServer and start the job manually  EPOS reference found box cannot be found.

  • Page 128: Troubleshooting When An Error Is Displayed

    Service manual Kona cutting plotter Troubleshooting Troubleshooting when an error is displayed 6.2.1 Errors with error number (ID 1009-6115) Error Message Description Solution Category The head is obstructed and can not move Remove the media or object blocking the head Fatal 1009 Y position error...
  • Page 129 Service manual Kona cutting plotter Troubleshooting Error Message Description Solution Category Y fuse is broken Check/replace fuse FU2  Y motor problem  Refer to Electronics > Mainboard on page 73 Mainboard driver problem  Refer to X and Y motor fuse on page 74 Fatal 1015 Y fuse error...
  • Page 130 Service manual Kona cutting plotter Troubleshooting Error Message Description Solution Category Check if the sheet-off system 1060 Sheet off error The front sensor is still covered after a sheet-off Warning Is the cutting blade still sharp? 2000 PG problem detected Media is too short to perform a PG action Load a longer sheet Warning...

  • Page 131: Contourcutting Errors And Warnings (Id 6201-6271)

    Service manual Kona cutting plotter Troubleshooting 6.2.2 Contourcutting errors and warnings (ID 6201-6271) When a specific contour cutting warning or error occurs, an error number will be displayed and a cross will be cut in the lower right corner. All codes are unique and the cross has a predefined angle and size to know of which nature the error is.
  • Page 132 Service manual Kona cutting plotter Troubleshooting Please find below an overview of the codes and category of problem A warning means that you will have the choice to continue cutting the current segment, all segments or to cancel the job. ...
  • Page 133 Service manual Kona cutting plotter Troubleshooting Error Message Description Solution Category One or more frame points lie outside hardclip region. Plot Outer pressure rollers are inside 6225 Possible data clip detected Warning data will be clipped. frame. Print distortion Original print distortion. No perfect rectangle, no parallel 6226 Bad print quality or outside specs.
  • Page 134 Service manual Kona cutting plotter Troubleshooting Error Message Description Solution Category Thickness problem All measured points of frame bottom vary too much from 6231 frame bottom each other! This will influence the accuracy of the cutting. Invalid thickness of P1 (right side of frame bottom). Thickness problem...
  • Page 135 Service manual Kona cutting plotter Troubleshooting Error Message Description Solution Category Thickness problem All measured points of frame top vary too much from each 6241 frame top other! This will influence the accuracy of the cutting. Invalid thickness of P5 (right side of frame top). Thickness Thickness problem...
  • Page 136 Service manual Kona cutting plotter Troubleshooting Error Message Description Solution Category Thickness problem Thickness of centre points (P9 & P10) differs too much from 6251 frame centre each other AND differs also from bottom points P1 and P4. Invalid thickness of P9 (right centre point). Thickness varies Thickness problem...
  • Page 137 Service manual Kona cutting plotter Troubleshooting Error Message Description Solution Category No valid frame found during fast scan routine (after several 6261 No valid frame found retries). Make sure all frame specifications are applied. To check: 6262 No valid frame found Only 1 frame point found during diagonal scan.

  • Page 138: Mgl Errors (Id 4000-5000)

    Parameter size overflow Error in HPGL command definition Label out of limit error other Unknown HPGL error Reinstalling the correct Mutoh Kona driver should solve this problem. Also be sure that the setting protocol is set to MGL. AP-74380 - Revision 1.1...

  • Page 139: Brevid_Error_Hw_Revision (6110-6120)

    Service manual Kona cutting plotter Troubleshooting 6.2.4 BREVID_ERROR_HW_REVISION (6110-6120) Signalisation An error will be displayed. Troubleshooting There has been loaded a wrong firmware for this mainboard. Error Possible reason Solution 6110 The board does not support the active firmware Update the mainboard with the correct firmware version Refer to Software and drivers >...

  • Page 140: Fpga Errors (6140 - 6150)

    Service manual Kona cutting plotter Troubleshooting 6.2.5 FPGA ERRORS (6140 - 6150) Signalisation There will be no error displayed. The cutter will not complete the start-up routine, however, the buzzer will sound. Troubleshooting The mainboard should be replaced Refer to Electronics >...

  • Page 141: Ram Errors

    Service manual Kona cutting plotter Troubleshooting 6.2.6 RAM ERRORS Signalisation There will be no error displayed. The cutter will not complete the start-up routine, however, the error LED (LD3R) on the mainboard will lit RED. Refer to Electronics > Mainboard > LED summary on page 73 Remove the right cover of the cutter to see the error LEDs.

  • Page 142: Other Errors

    Service manual Kona cutting plotter Troubleshooting 6.2.7 Other errors All the errors not mentioned in the previous chapters are internal processor errors and should be handled according to the flowchart mentioned below: Troubleshooting Back-up parameters Update firmware Reset to factory defaults Problem solved? Restore parameters...
  • Page 143 Service manual Kona cutting plotter Index Accuracy menu ..... . 113 Electronics ......67 Mainboard .

  • Page 144: Pressure Roller Assembly Replacement

    ... . . 138 Penhead cover removal procedure ..30 Mutoh CUTserver tests ....100 Tracking test .
  • Page 145 Service manual Kona cutting plotter RAM errros ......141 Uninstall the USB drivers ....96 Rear platen removal procedure, Covers USB drivers Rear platen removal...
  • Page 146 Service manual Kona cutting plotter AP-74380 - Revision 1.1...

This manual is also suitable for:

Kona 1650Kona 1400

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