Service Manual Kona - Rev 1.1

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!

Service manual Kona cutting plotter
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.
Mutoh furnished this document to support the Kona cutting plotter series. 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 nv
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.
AP-74380 - Revision 1.0 3

Parts replacement summary
The Service manual contains all necessary replacement procedures for every spare part
available for the Kona. Though, when replacing parts it might be possible that there are
additional actions necessary.
Please find below an overview:
1. Pen head replacement page 44

 Perform Y-Z measurement (diagnostics) page 93
 Adjust sheeting-off knife position page 91
 Perform EPOS calibration page 103
2. Mainboard replacement page 67

Before mainboard replacement
 Take back-up parameters using the Mutoh CUTserver page 98
After mainboard replacement
 Uninstall and reinstall USB drivers on PC page 96
 Load firmware via USB. page 94
 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
 Perform EPOS calibration page 103
3. Y-motor or Y speed reduction belt replacement page 35

 Adjust speed reduction belt to 3.5 kg page 87

4. X-motor replacement page 33

 Adjust belt tension to 3.5 kg page 86
5. Pressure roller assembly replacement page 61

 Adjust pressure of pressure rollers to 5,5 kg page 90
4 AP-74380 - Revision 1.0

Table of contents
Chapter 1 Regulations and safety information . . . . . . . . . . . . . 9
1.1 Warnings, cautions and notes . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Compliance with the following regulations . . . . . . . . . . . . . . 10
1.3 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Safety labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 2 Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Dimensions machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Installation environment requirements . . . . . . . . . . . . . . . . . . 14

 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
 Room conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Part names and functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4 Overview operation panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

 Main menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
 Settings or actions menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
 Adjust value menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5 Menu overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

 User mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
 Diagnostics mode 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.6 Machine version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Chapter 3 Part replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 Cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

 Side covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
 Y-rail cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
 Penhead cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
 Front platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
 Rear platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.2 X-motor and drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.3 Y-motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
 Y-motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
 Y-drive pulley and speed reduction belt . . . . . . . . . . . . . . . . . . . . . . 38
 Y-return pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.4 Penhead assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
 Penhead FFC (flexible flat cable). . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
 Penhead assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
 Penhead drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
 Sheet-off mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
 EPOS sensor block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
 Y-origin flex PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.5 Grit shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
 Grit shaft and support rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.6 Pressure roller assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
 Pressure roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
 Pressure roller assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.7 Cutting mat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.8 Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
 Mainboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
 X and Y motor fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
 Penhead PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
 Touchscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
 Vacuum fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Chapter 4 Adjustments and calibrations . . . . . . . . . . . . . . . . . 85
4.1 Mechanical adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

 X drive belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
 Y drive belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
 Penhead drive belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
 Pressure roller pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
 Sheeting-off knife position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
 YZ measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.2 Software and drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

 Download latest software and drivers . . . . . . . . . . . . . . . . . . . . . . . . 94
 Firmware installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
 How to uninstall the USB drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
 How to install the USB drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
 USB icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.3 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
 Backup parameters of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
 Restore parameters of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.4 Mutoh CutServer tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

 Tracking test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
 XY-distance accuracy test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.5 EPOS calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Chapter 5 Diagnostics mode . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.2 How to start up in diagnostics mode 1 and 2 . . . . . . . . . . . . 106

 Diagnostics 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
 Diagnostics 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.3 Menu overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
 Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
 PWM test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
 Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
 Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
 YZ profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
 Tool Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
 Aging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Chapter 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.1 Troubleshooting when no error is displayed . . . . . . . . . . . . 122

 General troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
 Recoverable error messages with no error ID number . . . . . . . . . 126
6.2 Troubleshooting when an error is displayed . . . . . . . . . . . . 128

 Errors with error number (ID 1009-6115) . . . . . . . . . . . . . . . . . . . . 128
 Contourcutting errors and warnings (ID 6201-6271) . . . . . . . . . . . 131
 MGL errors (ID 4000-5000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
 BREVID_ERROR_HW_REVISION (6110-6120) . . . . . . . . . . . . . 139
 FPGA ERRORS (6140 - 6150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
 RAM ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
 Other errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Regulations and safety information
Chapter 1 Regulations and
safety information
Warnings, cautions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1
Compliance with the following regulations . . . . . . . . . . . . . . . . . . . . . . . 10
Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.1 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).
Read the following explanations carefully and follow the instructions in this manual.
Safety terms Details

Important Must be followed carefully to avoid death or serious bodily injury.
Must be observed to avoid bodily injury (moderate or light) or damage to
Caution
your equipment.
Contains important information and useful tips on the operation of your
Notes
cutter.
1.2 Compliance with the following regulations

The CE marking is a mandatory European marking for certain
product groups to indicate conformity with the essential health and
safety requirements set out in European Directives.
By affixing the CE marking, the manufacturer, his authorized

representative, or the person placing the product on the market or
putting it into service ensures that the item meets all the essential
requirements of all applicable EU directives and that the applicable
conformity assessment procedures have been applied.
This product is tested and approved by the Canadian Standards

Association (CSA), this to provide increased assurance of quality and
safety.
The product is tested according to IEC60950.

This standard tries to cover all safety aspects.
 Mechanical, electrical
 Choice of components
 Choice of materials: flammability!
 Connectors, cables …
 Fire enclosure
 …
This means the product is safe for users, service personnel and
production personnel.
CSA International certification is not a legal commitment but it

assures the quality and safety of the machine.
10 AP-74380 - Revision 1.1

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.
Please inform yourself about the local separate collection system for
electrical and electronic products. 1
Please act according to local rules and do not dispose of your old
products with your normal household waste. The correct disposal of
your old product will help prevent potential negative consequences
for the environment and human health.
This equipment has been tested and found to comply with the limits
for a Class A digital device, pursuant to Part 15 of the FCC Rules.
These limits are designed to provide reasonable protection against
harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
FCC frequency energy and, if not installed and used in accordance with
the instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is
likely to cause harmful interference in which case the user will be
required to correct the interference at his own expense.
ICES This Class A digital apparatus complies with Canadian ICES-003.
1.3 Important notes

 This machine has a double pole / neutral fusing.
 Technical problems and maintenance, which require the cutter to be opened, can only be
done by qualified personnel who were trained to repair this type of machine.
 Unauthorized removing of covers and/or overruling safety locks can be dangerous and will
result in your guarantee becoming void.
 After powering OFF the machine, wait at least 10 seconds before powering ON again. Not
respecting this time interval could damage the machine.
 The cutter must be connected to an earthed mains socket-outlet.
AP-74380 - Revision 1.1 11

1.4 Safety labels

Label Description
Be careful not to get stuck between the
following moving parts:
 Cutting head
 Grit rollers
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.
12 AP-74380 - Revision 1.1

Product overview
Chapter 2 Product overview

Dimensions machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation environment requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 14

 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2
 Ambient conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
 Room conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Part names and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Overview operation panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

 Main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
 Settings or actions menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
 Adjust value menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Menu overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
 User mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
 Diagnostics mode 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Machine version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
AP-74380 - Revision 1.1 13

Product overview
2.1 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”
Height 275 mm / 10,8” 1150 mm / 45,3” 1150 mm / 45,3”
Weight (options excl.) 21 kg / 46,3 lb 48 kg / 105,8 lb 52 kg / 114,6 lb
Weight (options incl.)
 Media support rolls
40 kg / 88,9 lb 56 kg / 123,5 lb 63 kg / 138,9 lb
 Media basket
 Roll off system
2.2 Installation environment requirements

2.2.1 Power supply
 Voltage 100-240 V AC
 Current 1,5 A
 Frequency 50-60 Hz
Humidity (%)
2.2.2 Ambient conditions
Operation environment
75
 Temperature: 10°C - 35°C 70
 Humidity: 35% - 75% non-condensing
Recommended environment (dark area)
 Temperature: 16°C - 32°C

35
 Humidity: 35% - 70% non-condensing
Variation rate
 Temperature: 2°C per hour

 Humidity: 5% per hour
10 16 32 35 T(°C)
Storage environment
 Temperature: 0°C - 50°C
14 AP-74380 - Revision 1.1

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
obstructed.
2
 Avoid unnecessary vibrations and set up your cutter on a level surface.
 Be sure to have some free space on each side of the Kona to ease the operating of it.
d b
a
c
 a = at least 1 meter
 b = at least 1 meter
 c = at least 1 meter
 d = at least 0,2 meter
AP-74380 - Revision 1.1 15

Product overview
2.3 Part names and functions
N° Description Extended description
1 Pressure rollers To push the media against the grit rollers
A guiding platform with vacuum fans to transport

2 Media guide
the media as flat as possible during cutting
Provides a reliable cutting surface and minimizes

3 Cutting mat
damage to the knife tip
Rollers with a granular surface to move the media

4 Grit rollers
front and backwards
5 Control panel touch screen To make various settings before and during cutting
Assembly of cutting knife, sheet-off mechanism and

6 Cutting head
EPOS sensor
7 USB inlet To connect the USB cable
8 Power inlet and power switch To connect the power cable and power on the unit
9 Roll conveyor To support and roll-off the vinyl
10 Stand and wheels To move the cutter easily
11 Media bag To collect the media when sheeting off
12 Roll-off system To roll-off pre printed vinyl
13 Pressure roller lever To lower and raise the pressure rollers
16 AP-74380 - Revision 1.1

Product overview
2.4 Overview operation panel

2.4.1 Main menu
1 Settings button Open the settings menu 1/4
2 Actions button Open the actions menu 1/2
This icon will appear as from the

moment the Kona is connected via USB
3 USB indication
to the computer AND the correct drivers
are installed.
4 Play / pause button Pause or resume a job
5 Cancel button Cancel a job
AP-74380 - Revision 1.1 17

Product overview
2.4.2 Settings or actions menu
1 Home button Go back to the home menu (the menu shown above)
4 Back / cancel button Go back to the previous menu in the hierarchy
5 Previous button Go back to the previous page within a menu level
6 Next button Go to the next menu page within a menu level
7 Menu button Open the respective menu
18 AP-74380 - Revision 1.1

Product overview
2.4.3 Adjust value menu
1 Home button Go back to the home menu (the menu shown above)
Go back to the previous menu in the hierarchy and/or cancel

4 Back / cancel button
the settings change
5 Numeric keyboard Type the requested set value
6 Save button Save the new value
7 Decrease button Decrease the value with one digit
8 Increase button Increase the value with one digit
9 Erase button Delete the last digit
10 Erase all button Erase the complete value
Note
 It is impossible to exceed a maximum value. The cutter will beep twice if you
try.
 The value will be displayed in blue when the chosen value is smaller than the
minimum value.
AP-74380 - Revision 1.1 19

Product overview
2.5 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 20 - 100 - 450 g
Test
Tool Drag knife
Pen
Load mode With front
Without front, uneven media
With front, uneven media
Without front
Load Length 100 - 1000 - 10000 mm
Settings 2/4 Smoothing On
Off
Prefeed 0 - 1000 - 10000 mm
Sheet off Mode Automatic
Manual
Disabled
Margin 1 - 5 - 250 mm
Velocity 10 - 60 - 100 cm/s
Max. length 0 - 2000 - 10000
Job Focus Accuracy
Speed
Auto shuffle On
Off
Origin Center
Lower right
Lower left
Upper right
Upper left
Page Mode 0-1-2
20 AP-74380 - Revision 1.1

Product overview

Settings 3/4 Epos Alignment Automatic
Manual
Language English
Greek
Polski
Portugues
Italiano 2
Espanol
Deutsch
Francais
Nederlands
Protocol Emulation HPGL2
HPGL
MHGL2
MHGL
VS/ZF/AS Accept
Ignore
Resolution 0.010 mm
0.025 mm
Swap Alert Singletool / multitool
Cut Through Velocity 1 - 15 - 100 cm/s
Force 20 - 250 - 450 g
Test
Up Distance 0.1 - 2.0 mm
Down Distance 0 - 10 - 100 mm
Epos Alignment Automatic
Manual
Settings 4/4 Diagnostics Refer to Diagnostics mode 1 and 2 on page 23
Screen Beep Off
On
Contrast 0 - 25 - 40%
Brightness 0 - 50 - 100%
Animation Wait Time
Play
Defaults Yes / No
Information Firmware
Machine
Company
User
AP-74380 - Revision 1.1 21

Product overview

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
EPOS Read
Sheet-off Yes / No
Actions 2/2 Copies 0 - 1 - 100
22 AP-74380 - Revision 1.1

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
X
Connection
Y
X
2
Encoder Y
Z
X
PWM test Y
Z
User
Defaults
Machine
X
Accuracy
Y
YZ profile
Measure
Tool Force
Verify
Laser
Fan
Actuators
Buzzer
Leds
Media front left
Media front right
Media rear
Lever
Sensors
Pinch flap
Dip switches
XY voltage
EPOS
Tool
Aging Sheet off
Cut through
VCM
Screen
Touchfield
AP-74380 - Revision 1.1 23

Product overview
2.6 Machine version

Each machine has its own version number existing
out of a letter (version) and a number (revision),
e.g. A2.
 Some parts integrated in a machine with a
higher version number, might not be
downwards-compatible with machines
containing a lower version number.
 Example: Parts tagged with version C are NOT downwards compatible with machines
from version A and B
 Some parts integrated in a machine with a higher revision number, are downwards
compatible with machines containing a lower revision number.
Parts that are different due to different version-numbers, will be tagged on the sparepart-list,
with a serial number. (refer to the table below)
When spare parts have to be ordered, please always verify the serial-number on the cutter,
with those on the sparepart-list, to ensure you use the correct part!
Serial numbers Machine version number

LA-1909xx A1
LA-1910xx and LA-1911xx A2
LA-1912xx A3
LA-1001xx to LA-1007xx A4
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).
24 AP-74380 - Revision 1.1

Part replacement
Chapter 3 Part replacement

Important
3
 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
spare part.
 Refer to the latest spare part price list and exploded views to find the correct
partnumber and price.
Cover removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
 Side covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
 Y-rail cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
 Penhead cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
 Front platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
 Rear platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
X-motor and drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Y-motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
 Y-motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
 Y-drive pulley and speed reduction belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
 Y-return pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Penhead assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
 Penhead FFC (flexible flat cable). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
 Penhead assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
 Penhead drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
 Sheet-off mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
 EPOS sensor block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
 Y-origin flex PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
AP-74380 - Revision 1.1 25

Part replacement
Grit shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
 Grit shaft and support rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Pressure roller assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
 Pressure roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
 Pressure roller assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Cutting mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
 Mainboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
 X and Y motor fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
 Penhead PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
 Touchscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
 Vacuum fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
26 AP-74380 - Revision 1.1

Part replacement
3.1 Cover removal
2 3
4
1
5 3
6
N° Description Get access to the following parts Removal procedure
1  Belt return pulley assy

Left cover page 28
 Grit shaft drive pulley and belt
2  Penhead assembly
 Head FFC (flex flat cable)
Y-rail cover page 29
 Pressure roller assembly
 Touchscreen assembly
3  Rear paper sensor

Rear platen  Power supply page 32
 X-motor assembly
4  EPOS block
 Sheet-off assembly
Penhead cover  Penhead assembly page 30
 Penhead board
 Y-origin flex PCB
5  Y-motor assembly
 Speed reduction pulley
Right cover  Pressure roller up/down sensor page 28
 Mainboard flatcables
 Power inlet
6  Paper front sensors (2)

Front platen  Mainboard page 28
 X-motor connector
AP-74380 - Revision 1.1 27

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

Part replacement
3.1.2 Y-rail cover
Tools necessary
 P2 screwdriver
Removal procedure
Step 1: Remove on of the side covers first. 3

Step 2: Loosen the 4 screws fixing the Y-rail cover.
4x
Step 3: Remove the Y-rail cover.
AP-74380 - Revision 1.1 29

Part replacement
3.1.3 Penhead cover
Tools necessary
 P2 screwdriver
Removal procedure
Step 1: Remove side covers and Y-rail cover first

Refer to Cover removal > Y-rail cover on page 29
Step 2: Remove the 3 screws fixing the penhead cover.
3x
Step 3: Remove the penhead cover.
30 AP-74380 - Revision 1.1

Part replacement
3.1.4 Front platen
Tools necessary
 P2 screwdriver
Removal procedure
Step 1: Remove the side covers, Y-rail cover and penhead cover. 3
Refer to Cover removal > on page 27
Step 2: Remove the 3 screws fixing the front platen.
3x
Step 3: Loosen the screw at the left and right side pushing down the front platen.
Step 4: Remove the front platen carefully. It might be necessary to move the penhead
during removal.
Reassembling notes
Step 1: Position the head in the middle of the print platform.

Step 2: Hook the front platen over the front sensors.
Step 3: Push the plate back in its original position and tighten the screws at the front and
then sides.
AP-74380 - Revision 1.1 31

Part replacement
3.1.5 Rear platen
Tools necessary
 P2 screwdriver
Removal procedure
Step 1: Remove the following covers first:

 Side covers
 Y-rail cover
Step 2: Remove the 3 screws fixing the rear platen.
3x
Step 3: Lower the pressure rollers.

Step 4: Remove the rear platen.
32 AP-74380 - Revision 1.1

Part replacement
3.2 X-motor and drive belt

Tools necessary
 P2 screwdriver
Replacement procedure
Follow the procedure below to replace the X-motor and/or drive belt.
3
 Left cover
 Front platen
Refer to Cover removal > Front platen on page 31
 Rear platen
Refer to Cover removal > Rear platen on page 32
Step 2: Remove the 2 screws fixing the X-motor assembly.
Step 3: Disconnect the cable at the front side of the cutter.
AP-74380 - Revision 1.1 33

Part replacement
Step 4: Replace the motor and cable.

Step 5: Remove the grounding bracket.
Step 6: Replace the drive belt.
Adjustments necessary
After replacing this part, it is necessary to make the following adjustment.
N° Description Link
1 X drive belt tension Mechanical adjustments on page 86
34 AP-74380 - Revision 1.1

Part replacement
3.3 Y-motor assembly

3.3.1 Exploded view
1
2
3
3
rear
front
front
rear
N° Description Replacement procedure
1 Y-motor page 36
2 Y-drive pulley page 38
3 Speed reduction belt page 39
4 Y-return pulley page 39
AP-74380 - Revision 1.1 35

Part replacement
3.3.2 Y-motor
Tools necessary
 P2 screwdriver
Follow the procedure below to replace the Y-motor.

 Right cover
 Front platen
Step 2: Remove the 2 screws fixing the Y-motor.
36 AP-74380 - Revision 1.1

Part replacement
Step 3: Disconnect the following cables:
 From motor to mainboard

 From motor to lever up/down sensor
Step 4: Put the lever in the down position.
Step 5: Gently tilt out and replace the Y-motor.
1 Y drive belt tension Mechanical adjustments on page 87
AP-74380 - Revision 1.1 37

Part replacement
3.3.3 Y-drive pulley and speed reduction belt
Tools necessary
 P1 and P2 screwdriver
Follow the procedure below to replace the Y-drive pulley and speed reduction belt.
Step 1: Remove all covers except the front and rear platen
Refer to Cover removal on page 27
Step 2: Remove the penhead assembly
Refer to Penhead assembly > Penhead assembly on page 44
Step 3: Loosen penhead drive belt
Refer to Penhead assembly > Penhead drive belt on page 47
Step 4: Remove the Y-motor
Refer to Y-motor assembly > Y-motor on page 36
Step 5: Loosen the screw fixing the Y-drive pulley.
Step 6: Replace the Y-drive pulley and/or speed reduction belt.
2 Penhead drive belt tension Mechanical adjustments on page 88
38 AP-74380 - Revision 1.1

Part replacement
3.3.4 Y-return pulley
Tools necessary
 P2 screwdriver
Follow the procedure below to replace the Y-return pulley. 3

 Left cover
 Y-rail cover
Step 3: Loosen penhead drive belt
Refer to Penhead assembly > Penhead drive belt on page 47
Step 4: Loosen the 2 screws fixing the Y-return pulley.
Step 5: Turn the Y-return pulley shaft 90 degrees and remove the metal sockets.
Step 6: Remove and replace the Y-return pulley.
AP-74380 - Revision 1.1 39

Part replacement
3.4 Penhead assembly

3.4.1 Exploded view
1
2
3
6
1 Penhead FFC (flexible flat cable) page 41
2 Penhead PCB page 75
3 Penhead drive belt page 47
4 Sheet-off mechanism page 49
5 EPOS sensor block page 50
6 Y-origin flex PCB page 52
40 AP-74380 - Revision 1.1

Part replacement
3.4.2 Penhead FFC (flexible flat cable)
Tools necessary
 P2 screwdriver
 Snap-off blade
3
Follow the procedure below to replace the penhead FFC.
 Right cover
 Y-rail cover
 Penhead cover
Refer to Cover removal > Penhead cover on page 30
Step 2: Remove the 2 screws of the flatcable bracket.
Step 3: Disconnect the flatcable.
AP-74380 - Revision 1.1 41

Part replacement
Step 4: Carefully loosen the flatcable guider (only for Kona 1400 and 1650). Be careful not
to bend the guider and to cut in the flatcable!
Step 5: Loosen the 2 brackets fixing the flatcable at the right side of the cutter.
Step 6: Unplug the flatcable from the mainboard and replace it.
42 AP-74380 - Revision 1.1

Part replacement
Reassembling notes
Step 1: Move the penhead to the far left of the machine and press it against the pen until the
sheet-off knife is pushed out completely.
Step 2: Mount the flatcable to the penhead PCB and fix the flatcable bracket.
Step 3: Start guiding the flatcable in the gutter until you reach the middle (where no double
sided tape is installed).
Step 4: Adjust the flatcable position until it does not interfere with the Y-return pulley
bracket. If you do not install the flatcable correctly, it might be damaged during 3
cutting.
Step 5: Guide the flatcable through the cutter to the right side.
Step 6: Stick the flatcable onto the double side tape.
Step 7: Bend the flatcable in an angle of 90° and fix the flatcable bracket as shown below:
Step 8: Plug the flatcable in the mainboard. Be sure the flatcable is installed rectangularly.
AP-74380 - Revision 1.1 43

Part replacement
3.4.3 Penhead assembly
Tools necessary
 P2 screwdriver
 Hexagon wrench 5,5 mm
 Hexagon key 2,5 mm
Follow the procedure below to remove the penhead assembly.

Step 2: Remove the following covers first
 Side covers
 Y-rail cover
 Penhead cover
Step 3: Disconnect the 3 flex cables.
Step 4: Loosen the two hexagon spacers.
Step 5: Move the penhead to the middle of the machine.
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Part replacement
Step 6: Remove the screw fixing the penhead to the drive belt.
Step 7: Remove the screw on top of the penhead.
Step 8: Remove the leaf spring.
Step 9: Remove penhead assembly by tilting it of the Y-rail.
AP-74380 - Revision 1.1 45

Part replacement
After replacing/removing this part, it is necessary to make the following adjustment.
1 EPOS calibration EPOS calibration on page 103
2 YZ profile YZ measurement on page 93
Reassembling notes
Pay attention to the order of the installation of the leaf spring, washer and screw.
Step 1: Install the leaf spring.

Step 2: Install the washer.
Step 3: Tighten the screw.
46 AP-74380 - Revision 1.1

Part replacement
3.4.4 Penhead drive belt
Tools necessary
 P2 screwdriver
3
Follow the procedures below to replace the penhead drive belt.
 Side covers
 Y-rail cover
 Penhead cover
Step 3: Loosen the 2 screws fixing the Y-return pulley equally. This will ease the adjustment
of the penhead drive belt afterwards.
Step 4: Turn the Y-return pulley shaft 90 degrees.
AP-74380 - Revision 1.1 47

Part replacement
Step 5: Remove the 4 screws of the drive belt connection plate.
Step 6: Replace the penhead drive belt.
48 AP-74380 - Revision 1.1

Part replacement
3.4.5 Sheet-off mechanism
Tools necessary
 P2 screwdriver
Step 1: Remove the 2 screws fixing the sheet-off mechanism. 3
Step 2: Replace the sheet-off mechanism.

Refer to the User’s Guide to know how to replace the sheet-off blade only.
1 Sheet-off knife position Mechanical adjustments on page 91
AP-74380 - Revision 1.1 49

Part replacement
3.4.6 EPOS sensor block
Tools necessary
 P2 screwdriver
Follow the procedure below to replace the EPOS sensor block.

 Side covers
 Y-rail cover
 Penhead cover
Step 3: Disconnect the EPOS sensor flatcable from the PCB board.
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Part replacement
Step 4: Remove the screw fixing the EPOS sensor block.
Step 5: Replace the EPOS sensor block.
AP-74380 - Revision 1.1 51

Part replacement
3.4.7 Y-origin flex PCB
Tools necessary
 P2 screwdriver
Follow the procedure below to replace the Y-origin flex PCB.

 Side covers
 Y-rail cover
 Penhead cover
Step 2: Remove the penhead assembly.
Step 3: Loosen the 2 screws fixing the Y-origin flex PCB.
Step 4: Replace the Y-origin flex PCB.
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Part replacement
3.5 Grit shaft

3.5.1 Exploded view
2 1
1 Grit shaft page 54
2 Grit shaft bearings page 54
3 Grit shaft support rolls page 58
AP-74380 - Revision 1.1 53

Part replacement
3.5.2 Grit shaft and support rollers
Tools necessary
 Paper sheets (A5 - A4)

 Tape
 P2 screwdriver
 Loctite 641
 Hammer
Follow the procedure below to replace the grit shaft and support rollers.
Step 1: Remove all the covers of the cutter
Step 2: Be sure that the lever is in the UP position.
Step 3: Loosen the screws of the X-motor.
Step 4: Remove the screw fixing the grounding bracket
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Part replacement
Step 5: Install a piece of paper between the grit shaft and each support roll assembly to
avoid damaging them when pulling out the shaft later on.
Step 6: Loosen the 2 setscrews of the speed reduction pulley.
Step 7: Remove the speed reduction pulley and white spacer.

Step 8: Remove the 2 screws fixing the left bearing of the grit roll shaft.
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Part replacement
Step 9: Hammer out the grit shaft from the right side of the machine until the bearing at the
left comes out.
Step 10: Remove the grit shaft assembly.

Step 11: Remove the 2 screws fixing the right bearing of the grit roll shaft.
Step 12: Remove the bearing at the right side of the cutter.
Step 13: Remove all screws fixing a grit shaft support roll and remove them.
56 AP-74380 - Revision 1.1

Part replacement
Reassembling notes
1. 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.
! !
3
2. When replacing the grit shaft, you will have to order a kit including the following items:
 Grit shaft
 2 bearings
 A set of grit shaft support rolls (quantity depends on the machine size)
3. Reinstall the grit shaft as follows:
Step 1: Clean both ends of the grit shaft with isopropanol and let it dry completely!
Left Right
Step 2: Clean the inside of the bearings with isopropanol and let it dry completely!
Step 3: Apply loctite 641 on the left side of the grit shaft. (refer to the picture above)
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Part replacement
Step 4: Install a bearing and push it as far as possible.
Step 5: Remove the spoiled glue.

Step 6: Install the grit shaft from left to right. Be careful not to damage the grit sections when
moving it through the hole in the left end plate.
Step 7: Apply loctite 641 on the right side of the grit shaft and install the right bearing.
Step 8: Fix the bearings with each two screws.
Step 9: Remove the spoiled glue on the inside

Step 10: Reinstall all parts previously removed in reverse order.
1 X drive belt tension Mechanical adjustments on page 86
58 AP-74380 - Revision 1.1

Part replacement
3.6 Pressure roller assembly

3.6.1 Exploded view
2
3
1 Pressure roller assembly page 61
2 Pressure roller page 60
AP-74380 - Revision 1.1 59

Part replacement
3.6.2 Pressure roller
Tools necessary
 Small screwdriver
Follow the procedure below to replace the pressure roller.

Step 1: Be sure that the pressure rollers raised.
Step 2: Push on the pressure roller shaft (left and right) until the pressure roller clicks out of
its base.
Step 3: Push down the pressure roller at the back of the machine and remove the roller with
a screwdriver.
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Part replacement
3.6.3 Pressure roller assembly
Tools necessary
 P1 and P2 screwdriver
3
Follow the procedure below to replace the pressure roller assembly.
Step 1: Remove all the covers of the cutter
Step 2: Remove the following parts first:
Part Procedure
Penhead Penhead assembly on page 44
Penhead drive belt Penhead drive belt on page 47
Y-motor Y-motor on page 36
Speed reduction belt and pulley Y-drive pulley and speed reduction belt on page 38
Touchscreen Touchscreen on page 80
Step 3: Loosen all flatcable brackets at the right side and unplug the flatcables.
Note
 Try not to bend the flatcables too much. Frequently folding the cables will
damage them.
AP-74380 - Revision 1.1 61

Part replacement
Step 4: Remove the hexagon pressure roller shaft as follows:

 Put the pressure rollers in the up position.
 Remove the shaft stop and spacer (at the left side) by loosening the set screw.
 Remove the two screws fixing the pressure roller lever.
 Remove the screw fixing the torsion spring (at the right side)
 Pay attention to the way the shaft is positioned at this moment. This to know how
to reinstall the shaft after replacing the pressure roller base.
62 AP-74380 - Revision 1.1

Part replacement
Step 5: Remove Y-rail as follows:

 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.
 Insert the drive belt in the Y-rail.

 Tilt out the Y-rail and be careful not to damage the flatcables.
 Support the Y-rail when laying it down on a table.
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Part replacement
Step 6: Mark the position of the end stop.
Step 7: Loosen the screw fixing the end stop and slide out the stop.
Step 8: Slide out the pressure roller assembly and replace it.
64 AP-74380 - Revision 1.1

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:
4 Pressure roller pressure Mechanical adjustments on page 90
AP-74380 - Revision 1.1 65

Part replacement
3.7 Cutting mat

Tools necessary
 Isopropanol
Please follow the procedure below to replace the cutting mat.

 Side covers
 Y-rail cover
 Penhead cover
Step 2: Draw a line in front of the cutting mat and remove the worn cutting mat.
Step 3: Clean the platen using isopropanol.

Step 4: Install the new cutting mat in the same position as the previous one.
Step 5: Reinstall the covers.
1 YZ calibration YZ measurement on page 93
66 AP-74380 - Revision 1.1

Part replacement
3.8 Electronics
3.8.1 Mainboard
Tools necessary
P2 screwdriver
3

 Set of pliers
 USB cable
 Mutoh CutServer and PC
Follow the procedure below to replace the mainboard.

Step 1: Store the current parameters using the Mutoh CutServer.
Refer to Parameters > Backup parameters of machine on page 98
 Right cover
 Front platen
Step 3: Unplug all connectors and flatcables. Note that the touchscreen flatcable has a
special connector. You should push up the lip of the connector before removing it.
AP-74380 - Revision 1.1 67

Part replacement
Step 4: Remove the 2 screws fixing the mainboard. (only for machine versions A1 and A2)
Refer to Machine version on page 24
Step 5: Push in all studs with a set of pliers, remove the mainboard and replace it.
Reassembling notes
Follow the procedure below to replace the flatcables correctly.

Step 1: Be sure that the lip of touchscreen flatcable connector is in the up position.
Step 2: Insert the flatcable.

Step 3: Push down the lip of the connector to secure the cable.
Step 4: Also be sure that the flatcables or mounted rectangularly.
68 AP-74380 - Revision 1.1

Part replacement
Uninstall and reinstall USB drivers on

1 Software and drivers on page 96
the PC
2 Load firmware Software and drivers on page 94

3
Restore parameters Restore parameters of machine on page 99
If there are no parameters available,

either perform the additional
adjustments mentioned below or
contact our service department
3 (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
AP-74380 - Revision 1.1 69

Part replacement
Board diagnostics
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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)
3
J10 (Sensors)
J1 (+48V) (fans)
Pin Pin name

1 + 48V
3 GND
J2 (rev A mainboards) or J12 (rev C mainboards) (to headboard)
Pin Pin name

1 AI_5V0_EPOS2
2 AI_5V0_EPOS1
3 GND
4 +5V0_FIL
5 DO_5V_OUT3
6 GND
7 IN5
8 GND
9 DI_5V0_ENC3B
10 GND
11 DI_5V0_ENC3A
12 GND
13 GND
14 DO_48V_OUT2
15 DO_48V_MOTOR3-
16 DO_48V_MOTOR3+
AP-74380 - Revision 1.1 71

Part replacement
J7 (X-motor and encoder)
Pin Pin name

1 V+
3 +5V
4 ENC_A
5 V-
7 GND
8 ENC_B
J8 (Y-motor and encoder)
Pin Pin name

2 V+
3 +5V
4 ECN_A
6 V-
7 GND
8 ENC_B
J9 (Power supply)
Pin Pin name

1 +48V
2 +48V
3 GND
4 GND
J10 (Sensors)
Pin Pin name

1 +5V0
2 nRear Paper
3 GND
4 +5V0
5 nFront Paper
6 GND
7 +5V0
8 nMid Paper
9 GND
72 AP-74380 - Revision 1.1

Part replacement
Pin Pin name

10 +5V0
11 nLever
12 GND
LED summary
LED Function
LD1 G +48 V 3
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-)
LD15 R Y motor (V-)
LD16 Y X motor (V+)
LD17 Y Y motor (V+)
Fuses summary
Connector Function LED

FU1 X Motor LD16 Y
FU2 Y Motor LD17 Y
Switch summary
Switch Function
SW1 RESET
DIP Switch summary
DIP Switch Function

DIP1 -
AP-74380 - Revision 1.1 73

Part replacement
3.8.2 X and Y motor fuse
Tools necessary
 P2 screwdriver
 Pair of tweezers
Follow the procedure below to replace the X or Y motor fuse

 Side covers
 Y-rail cover
 Penhead cover
 Front platen
Step 2: Remove the fuse with a pair of tweezer and replace it.
Note
 Fuse type
 Manufacturer: Littlefuse
 Serie: Slo-Blo Fuse 452/454
 Partnumber: R452002
 2A
74 AP-74380 - Revision 1.1

Part replacement
3.8.3 Penhead PCB
Tools necessary
 P2 screwdriver
3
Follow the procedure below to replace the penhead PCB.
 Side covers
 Y-rail cover
 Penhead cover
Step 2: Disconnect the 3 flex cables.
Step 3: Loosen the two hexagon spacers.
Step 4: Remove the 2 screws of the flatcable bracket and disconnect the flatcable.
Step 5: Replace the penhead PCB.
AP-74380 - Revision 1.1 75

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 Pin name

1 COIL+
2 COIL-
3 DO_48V_OUT2+
4 DO_48V_OUT2-
5 GND
6 CHA
7 GND
8 CHB
9 GND
10 DI_5V0_IN5
11 GND
12 DO_5V_OUT3
13 +5V0
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Part replacement
Pin Pin name

14 GND
15 AI_5V0_EPOS1
16 AI_5V0_EPOS2
J3 (EPOS)
Pin Pin name

1 +5V0 3
2 AI_5V0_EPOS2
3 GND
4 AI_5V0_EPOS1
5 GND
6 DO_5V_OUT3
J4 (Y-origin)
Pin Pin name

1 GND
2 nY-Origin
3 GND
4 +5V
J5 (PenHead)
Pin Pin name

1 CHB
2 +5V0
3 CHA
4 GND
5 GND
6 COIL+
7 COIL-
8 GND
9 GND
10 GND
11 GND
12 GND
AP-74380 - Revision 1.1 77

Part replacement
3.8.4 Power supply
Important
 Be sure to remove the power cable before servicing the power supply!
Tools necessary
 P2 screwdriver
Follow the procedure below to replace the power supply.

 Side covers
 Y-rail cover
 Penhead cover
 Rear platen
Step 2: Unplug all connectors.
Step 3: Remove the 2 plugs to get access to the 2 rear screws.
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Part replacement
Step 4: Depending on the machine version, a protective cover has been installed above the
power supply. Remove it before replacing the power supply.
Step 5: Remove the 4 screws fixing the power supply.
Step 6: Replace the power supply.
AP-74380 - Revision 1.1 79

Part replacement
3.8.5 Touchscreen
Tools necessary
 P2 screwdriver
Follow the procedure to replace the touchscreen.

 Right cover
 Y-rail cover
Step 2: Remove the screw fixing the touchscreen bracket.
Step 3: Remove the 2 screws fixing the touchscreen plastic cover.
Step 4: Unplug the flat touchscreen data cable.

Step 5: Replace the touchscreen or data cable.
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Part replacement
3.8.6 Sensors
Tools necessary
 P2 screwdriver
Pressure roller lever sensor
Follow the procedure below to replace the lever sensor. 3

Step 1: Remove the right cover.
Step 2: Disconnect the sensor cable.
Step 3: Remove the two screws fixing the sensor bracket.
Step 4: Replace the optical U-sensor.
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Part replacement
Front and middle paper sensor
Follow the procedure below to replace the front and middle paper sensor.
Step 1: Remove the front platen.
Step 3: Remove the screw fixing the sensor.

Step 4: Replace the paper sensor.
Rear paper sensor
Follow the procedure below to replace the rear paper sensor.

Step 1: Remove the rear platen.
Refer to Cover removal > Rear platen on page 32
Step 3: Remove the screw fixing the sensor.

Step 4: Replace the paper sensor.
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Part replacement
3.8.7 Vacuum fans
Tools necessary
 P2 screwdriver
 New cutting mat
3
Follow the procedure below to replace the vacuum fans.
 Side covers
 Y-rail cover
 Rear platen
Step 2: Remove the cutting mat.
Refer to Cutting mat on page 66
Step 3: Disconnect the fan cable.
Step 4: Remove the 4 screws fixing the vacuum fan.
Step 5: Replace the fan.

Step 6: Install new cutting mat.
Refer to Cutting mat on page 66
1 YZ calibration YZ measurement on page 93
AP-74380 - Revision 1.1 83

Part replacement
84 AP-74380 - Revision 1.1

Adjustments and calibrations
Chapter 4 Adjustments and

calibrations
Mechanical adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 4
 X drive belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
 Y drive belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
 Penhead drive belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
 Pressure roller pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
 Sheeting-off knife position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
 YZ measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Software and drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

 Download latest software and drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
 Firmware installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
 How to uninstall the USB drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
 How to install the USB drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
 USB icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
 Backup parameters of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
 Restore parameters of machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Mutoh CutServer tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

 Tracking test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
 XY-distance accuracy test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
EPOS calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
AP-74380 - Revision 1.1 85

4.1 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.
Step 1: Loosen the 2 screws fixing the X-motor assembly.
Step 2: Attach a piece of rope around the motor body, through the hole as close as possible
to the side plate.
Step 3: Pull the bar tension gauge (range 5kg) in the direction of the slotholes for and
tighten the 2 screws when reaching the value: 3.5 kg ± 0.05 kg.
86 AP-74380 - Revision 1.1

4.1.2 Y drive belt tension
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
4
Pressure roller assembly replacement Pressure roller assembly on page 61
Follow the procedure below to adjust the tension of the Y-drive belt.
Step 1: Loosen the 2 screws fixing the Y-motor assembly.
Step 2: Attach a piece of rope around the motor body as close as possible to the side plate.
Step 3: Pull the bar tension gauge (range 5kg) perpendicularly for 3.5 kg ± 0.05 kg.
Step 4: Move the cutting head manually left and right a few times before fixing the motor
screws while holding the tension gauge under a constant pressure of 3.5 kg.
AP-74380 - Revision 1.1 87

4.1.3 Penhead drive belt tension
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
Follow the procedure below to adjust the tension of the penhead drive belt.
Step 1: Move the penhead from the far left to the far right of the machine. The penhead
drive belt position on the Y-return pulley should remain the same. If it is moving up
and down, adjust the two screws fixing the Y-return pulley.
Step 2: Park the penhead at the left side of the machine.
88 AP-74380 - Revision 1.1

Step 3: Measure with a bar tension gauge (range: 500 g) the tension of the belt in the
middle of the Y-rail. Push the belt with the bar tension until it touches the rail and
release gently the pressure on the gauge. When the belt starts to release from the
rail is the moment of reading the value on the bar tension gauge. 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.
For Kona 1650 the value should be 95 g ± 5 g.
4

Step 4: If the value is out of range, turn the two screws of the Y-return pulley an equal
amount to the left or right.
AP-74380 - Revision 1.1 89

4.1.4 Pressure roller pressure
Part Link
Follow the procedure below to adjust the pressure of the pressure roller assembly.
Step 1: Make sure that the pressure rollers are raised.
Step 2: Position the pressure roller above a grit roll.
Step 3: Take a piece of polyester film and put it between the grit roller and the pressure
roller. Attach the bar tension gauge (range 5 kg) under the pressure roller in line
with the grid roll axis.
Step 4: Lower the pressure rollers.
Step 5: Pull simultaneously at the film and the tension gauge.
Step 6: The moment that the film starts slipping between the rollers is the moment to read
the value on the tension gauge. The value should be 5,5 kg ± 0,1 kg.
Step 7: Adjust the pressure moving the nuts up (decrease pressure) or down (increase
pressure).
90 AP-74380 - Revision 1.1

Step 8: Be sure to fasten the nuts to each other and verify the pressure once more.
4.1.5 Sheeting-off knife position
Part Link
Penhead assembly replacement Penhead assembly on page 44
Sheeting-off mechanism Sheet-off mechanism on page 49
Follow the procedure below to adjust the position of the sheeting-off knife.
Step 1: Loosen the 2 screws fixing the sheet-off mechanism. Be sure that there is still some
friction between penhead and sheet-off bracket.
Step 2: Remove the penhead cover.

Refer to Cover removal > Penhead cover on page 30
AP-74380 - Revision 1.1 91

Step 3: Adjust the sheet-off knife height so that the metal bracket of the spring-wheel
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.
Step 4: Adjust the sheet-off knife front and backwards so that the knife is positioned in
between the cutting groove and does not touch the sides.
Step 5: Tighten the screws when the adjustment has been finished.
92 AP-74380 - Revision 1.1

4.1.6 YZ measurement
Part Link
Cutting mat replacement Cutting mat on page 66
Vacuum fan replacement Vacuum fans on page 83

4
Penhead replacement Penhead assembly on page 44
Refer to Menu overview > YZ profile on page 114 to know how to perform the adjustment
procedure via diagnostics mode.
AP-74380 - Revision 1.1 93

4.2 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
Step 1: Make a connection between the Kona and your computer using a USB cable. Be
sure that the USB driver has been installed yet!
Step 2: Power ON the cutter and computer.
Step 3: Launch the exe file you have downloaded.
Step 4: Press next.
Step 5: Read the License Agreement and select I accept the agreement and press next.
Step 6: Click Install to continue.
Step 7: The program will extract the files.
Step 8: Select the ComPort on which the cutter is connected and press Apply.
Step 9: The PC will send the new firmware to the cutter.
Step 10: When the file is sent, the programming will start. 
Be sure NOT to shut down the cutter during this routine!
Step 11: The Kona will restart automatically as soon as the firmware has been installed.
94 AP-74380 - Revision 1.1

Step 12: The machine will restart automatically.
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. Solve this issue by sending the firmware file once
again.
Step 13: Verify that the firmware and drivers has been updated correctly. The firmware
version will be displayed in the upper left corner of the mainscreen.
4
AP-74380 - Revision 1.1 95

4.2.3 How to uninstall the USB drivers
Step 1: Make sure your Kona is powered ON and connected to the PC.
Step 2: In the Device manager you will find your device
 Virtual serial port
 USB device
Step 3: Uninstall the serial PORT

 Double-click on the USB serial port item and select the driver TAB
 When you want to install a new version of the driver press the update driver
button.
 When you want to remove the complete driver press on the uninstall button.
Step 4: Perform the same actions to uninstall/update the USB device
Step 5: When the driver is uninstalled successfully, the virtual serial port and the USB
device will be removed from the device manager lists.
96 AP-74380 - Revision 1.1

4.2.4 How to install the USB drivers
Step 1: Make a connection between the Kona and your computer using a USB cable
(standard in-the-box item).
Step 2: Power ON the cutter and computer.
Step 3: Your computer will automatically detect the cutter.
Step 4: When your are asked to connect to search automatically for software, select No, not
this time and press Next.
4
Step 5: Choose Install from a list or specific location and press next to continue.
Step 6: Browse to the folder with USB drivers you have downloaded from Mutoh’s FTP.
Step 7: Windows will search the hardware.
Step 8: When working with Windows Vista or 7, a warning message will be displayed.
Ignore this message and press Continue anyway.
Step 9: The software will be installed.
Step 10: After the installation of the cutter itself, the USB serial port driver need to be
installed.
Step 11: Perform the same procedure as for the Kona cutter.
Step 12: If installation is completed successfully, the following text-balloon will pop up.
4.2.5 USB icon
As from the moment the drivers are installed correctly and there has been established a
connection between the PC and Kona, an USB icon will appear in the main screen. If not, the
USB drivers are not installed properly or the USB cable is not connected.
AP-74380 - Revision 1.1 97

4.3 Parameters
It can always be interesting to be able to fall back on parameters previously stored when
having problems with the machine or when servicing the machine (for example a mainboard
change). Please follow the procedure below to backup and restore the parameters. Please
note that this is only possible in combination with the Mutoh CutServer.
4.3.1 Backup parameters of machine
Step 1: Be sure that:

 the cutter is powered 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
Step 2: Right-click on the opened connection and choose to take a backup from this
machine...
Step 3: A screen will appear in which a file name can be chosen. You can choose the file
name your own or you can leave this field blank. The Mutoh CutServer will
automatically create a name. Press OK to continue.
Step 4: Another dialogue window will appear when the backup has been succeeded
successfully.
Step 5: You can find the backup file in a specified folder "Backup" of the Mutoh CutServer.
You can browse to the folder on either of these two ways:
 Installation folder of the Mutoh CutServer
C:\Program Files\Mutoh Europe NV\CUTserver\backup
 Mutoh CutServer help menu > show backup files.
98 AP-74380 - Revision 1.1

4.3.2 Restore parameters of machine

Step 2: Right-click on the opened connection and choose to restore backup to a machine...
4
Step 3: An overview of the available files will be displayed.

 Double click on the back-up you want to be installed.
 Double click on the COM port to which the cutter is connected.
Step 4: The settings will be restored and the machine will reboot automatically. This may
take a few minutes.
Step 5: Check the settings and confirm if the restore has been finalised successfully.
AP-74380 - Revision 1.1 99

4.4 Mutoh CutServer tests

4.4.1 Tracking test
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
 Humidity between 35% and 75%, non-condensing
 Media on the conveyor rolls
 Bags are closed
 Used media has been acclimatised for at least two hours
 The media is wound up straight on the core.
 The force is 100 gram
It is very important that the media does not interfere with any obstacles during the test!
Please follow the procedure below to perform and evaluate the test:
Step 2: Select which tracking test to perform.
Step 3: Select the appropriate COM-port and double-click.
Step 4: Load a knife.

Step 5: Load a roll or sheet with at least the following measurements.
 For Tracking Test Small (min 500 mm x 4050 mm)
 For Tracking Test Large (min 1250 mm x 4050 mm)
Step 6: Lever down.
100 AP-74380 - Revision 1.1

Step 7: The following pattern will be cut. Evaluate the test file as follows:
When you see the following pattern

(slight deformation to the left), the
tracking of the machine is not good. See
below for fixing the problem.
4
The tracking test has been finished

perfectly. All boxes have been cut
exactly on the same line.
When you see the following pattern

(slight deformation to the right), the
tracking of the machine is not good. See
below for fixing the problem.
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
procedure.
 Be sure that the grit rollers are not covered with dirt.
 Be sure that the grit rollers are not damaged or worn out.
 Be sure that the pressure of the pressure rollers is correct.
Refer to Mechanical adjustments > Pressure roller pressure on page 90
 Be sure that the pressure rollers are not damaged or worn out.
 Be sure to use all pressure rollers during this test.
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4.4.2 XY-distance accuracy test
The XY - Distance Accuracy tests are developed to check the actual X-Y cutting distance with
the sent vector data.
Please follow the procedure below to make the test:
Step 1: Launch Mutoh’s CUTserver.
Step 2: Be sure that the cutter is connected with the Mutoh CUTserver.
Step 3: Select which test to perform.
Step 4: Select the appropriate COM-port and double-click.
Step 5: Load a roll or sheet with at least the measurements indicated in the dropdown
menu.
Step 6: Load a knife.
Step 7: A box will be cut.
Step 8: Peel out the box.
Step 9: Measure the X length and Y width and enter them. Be sure to enter the values in
mm!
Step 10: If the correct values have been entered, the following message will appear and the
test will be done.
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4.5 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.
Note
 Each time a new tool is installed, this test should be performed. 4
Step 1: Install and set a knife.
Step 2: Install a dark (black) vinyl.
Step 3: Press the following buttons in order:
 Settings
 1 x previous page
 Epos Align
Automatic alignment Manual alignment

Step 4: Select automatic Select manual
Step 5: Press the start key Press the start key
Step 6: The following pattern will be cut: The following pattern will be cut:
Step 7: The machine will present the test The machine will present the test
pattern by feeding the vinyl pattern by feeding the vinyl
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Automatic alignment Manual alignment

Step 8: Weed out the square and press OK Weed out the squares and press OK
Step 9: The cutter will automatically measure The EPOS laser will be activated and
the bottom and right side of the box, to will move to the approximate centre of
know the distance between the EPOS the cross. Guide the laser to the
sensor and the knife tip. perfect centre (if necessary) of the two
squares and confirm the position with
OK.
Step 10: The EPOS calibration has been The EPOS calibration has been
finished. finished.
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Diagnostics mode
Chapter 5 Diagnostics mode

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
How to start up in diagnostics mode 1 and 2 . . . . . . . . . . . . . . . . . . . . 106

 Diagnostics 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5
 Diagnostics 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Menu overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

 Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
 Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
 PWM test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
 Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
 Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
 YZ profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
 Tool Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
 Aging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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Diagnostics mode
5.1 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).
Please read this chapter thoroughly to know how to enter both these diagnostics modes and
how to perform several tests.
5.2 How to start up in diagnostics mode 1 and 2

5.2.1 Diagnostics 1
Step 1: Power on the machine at the side.

Step 2: Wait until the Kona has been initialized.
Step 3: Press the following buttons in order:
 Settings
 1 x previous page
 Diagnostics
Step 4: Press enter when the following screen appears to access diagnostics mode 1
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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.
Step 1:
Step 2:
Power ON the machine at the side.
Press on the touchscreen in the lower right corner during start-up to enter
5
diagnostics mode 2.
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Diagnostics mode
5.3 Menu overview

Availability
Link
Diagnostics 1 Diagnostics 2
X
Connection Connection on page 109
Y
X
Encoder Y Encoder on page 110
Z
X
PWM test Y PWM test on page 111
Z
User
Defaults Defaults on page 112
Machine
X
Accuracy Accuracy on page 113
Y
YZ profile YZ profile on page 114
Measure
Tool Force Tool Force on page 115
Verify
Laser
Fan
Actuators Actuators on page 115
Buzzer
Leds
Media front left
Media front right
Media rear
Lever
Sensors Sensors on page 116
Pinch flap
Dip switches
XY voltage
EPOS
Tool
Aging Sheet off Aging on page 117
Cut through
VCM
Screen Screen on page 119
Touchfield
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Diagnostics mode
5.3.1 Connection
Via this menu it is possible to check the polarity of the X and Y motor.
Step 1: Go to diagnostics mode 1
Refer to Diagnostics 1 on page 106
Step 2: Be sure that the pressure rollers are raised.
Step 3: Press on the connection button
5
Step 4: Check if the cutter reacts as follows:
 When pressing on the X button, the grit shaft should move a quarter of a turn
forward. When it moves backwards, the + and - pole have been switched.
 When pressing on the Y button, the head should move 6 mm to the left. When
the head moves to the right, the + and - pole have been switched.
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Diagnostics mode
5.3.2 Encoder
When you are in doubt that the X, Y or Z encoder still functions, verify this as follows:
Step 1: Go to diagnostics mode 1 or 2
Step 2: Press on the encoder button
Step 3: Check if the values displayed changes as follows:
 X value
 Increases (+) when rotating the grit roller forward.
 Decreases (-) when rotating the grit roller backward.
 Y value
 Increases (+) when moving the head to the left.
 Decreases (-) when moving the head to the right.
 Z value
 Increases (+) when moving the pen/knife down.
 Decreases (-) when moving the pen/knife up.
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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:
Step 2: Press on the PWM test button
5
Step 3: Choose one of the three directions
 X = grit rollers
 Y = head
 Z = pen
Step 4: Increase or decrease the PWM value to check if the motor still works
 X-motor
 Increase (+) the value to rotate the grit rollers forward.
 Decrease (-) the value to rotate the grit rollers backward.
 The X-motor should react at a PWM between 150 and 300 with the pressure
rollers down. If not, the motor is broken or there is a mechanical interference.
 Y-motor
 Increase (+) the value to move the head to the left.
 Decrease (-) the value to move the head to the right.
 The Y-motor should react at a PWM between 100 and 150. If not, the motor is
broken or there is a mechanical interference.
 Z-motor
 Increase (+) the value to lower the pen/knife
 Decrease (-) the value to rotate the pen/knife
 The Z-motor should react at a PWM between 150 and 300. If not, the motor is
broken or there is a mechanical interference.
Step 5: As from the moment you press , the motor will stop.
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Diagnostics mode
5.3.4 Defaults
When establishing problems it might be necessary to reset the cutter. There are 2 levels of
resetting:
 User defaults: The most frequent end-user related settings
 Velocity setting
 Force setting
 Offset setting
 Shuffle length setting
 Tool type setting
 VS/ZF/AS setting
 Origin setting
 Language setting
 Sheet setting
 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
 Pen force calibration
Refer to the User’s Guide of the Kona
 YZ profile calibration
Refer to YZ measurement on page 93
 Touch screen calibration
Refer to the User’s Guide of the Kona
Proceed as follows to restore the user and or factory defaults
Note
 It is highly recommended to take a parameter backup before restoring the
machine settings.
Refer to Parameters > Backup parameters of machine on page 98

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Diagnostics mode
Step 2: Press on the Default button
Step 3: Choose the default you want to reset

 User defaults
 Machine defaults 5
Step 4: Confirm by clicking yes
Step 5: The machine will reboot and all settings will be reset.
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
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Diagnostics mode
5.3.6 YZ profile
Measure up the penhead height all across the width of the cutter. After the test, the cutter will
automatically save the parameters on condition that the values do not fluctuate too much.
Step 1: Install a knife that is completely screwed in!
Step 2: Be sure that the cutting mat is still in good shape and not worn out. Otherwise the
measurement will be incorrect.
Step 3: Unload media and be sure that the lever is up.
Step 4: Move the pressure rollers to the following position:
...
3 2 1
 Kona 760 - on grit roller 1 and 6

 Kona 1400 - on grit roller 1 and 5 and 11
 Kona 1650 - on grit roller 1 and 6 and 13
Step 5: Pull the lever down.
Step 6: Go to diagnostics mode 1.
Step 7: Press on the YZ profile button to start the measurement.
Step 8: The penhead will go down and move over the cutting mat from right to left.
Step 9: After the measurement, there are two possible conclusions:
 YZ Profile DONE
Measurement is completed successfully and the parameters have been saved.
 YZ Profile disapproved
The measured values fluctuate too much. The default parameters are loaded
again. Please contact our Service Department (service@mutoh.eu) for support.
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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. We only fine-tune them before shipping the cutters.
5.3.8 Actuators
When you are in doubt of the correct functioning of the 5

 EPOS laser
 Fans in paperguide
 Buzzer
 LED’s on the mainboard
verify it as follows:
Step 1: Go to diagnostics mode 1 or 2.
Step 2: Press on the Actuators button.
Step 3: Select the part you want to test.
Step 4: Change the value from off to on and verify if the laser, fans, buzzer or LEDs function
correctly.
Step 5: Press to return to the previous menu and deactivate the laser, fans, buzzer or
LEDs.
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Diagnostics mode
5.3.9 Sensors
When you are in doubt of the correct functioning of the sensors, verify it as follows:
Step 1: Go to diagnostics mode 1 or 2.
Step 2: Press on the Sensors button.
Step 3: The status of the sensors will be displayed:
Step 4: Manipulate the sensors as follows:
Sensor is covered
 Media Front Left
Sensor is uncovered
Sensor is covered
 Media Front Right
Sensor is uncovered
Sensor is covered
 Media Rear
Sensor is uncovered
Lever is down
 Lever
Lever is up
Head is in front of a pressure roller
 Pinch Flap
Head in not in front of a pressure roller
Dipswitch on mainboard is ON
 Dip Switches
Dipswitch on mainboard is OFF
 XY voltage 48V The value should be 48V ± 5% (45,6 V - 50,4V)
white The vinyl under the epos sensor is detected as
 EPOS (3rd value)
white
colour The vinyl under the epos sensor is detected as a
coloured one
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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.
5
Step 2: Press on the Aging button.
Step 3: Select the requested routine
Step 4: You can choose now between

 Reset to the defaults settings for this pattern only!
 Personalize the settings
 Pattern (number of patterns depends on the aging routine you have chosen)
 Iterations
 0 = until you stop the test manually
 1-... = dedicated number of times
 Distance X & Y
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Diagnostics mode
 Velocity
 Acceleration
 Force
 Tool Up or Down
 Start the aging test using the settings and pattern displayed
Step 5: After making the settings and pressing the play button, the cutter will cut the set
amount of test patterns.
Step 6: A count up (in case of infinite iterations) or count down (in case of specific amount of
iterations) screen will be displayed.
Note
 The cutting or sheeting-off routine can be aborted at anytime. However, the
cutter will finalize the current iteration first.
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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.
Press on the Screen button.
5
Step 2:
Step 3: Select which parameter to set
VCM value This value is by default set to 95. For the majority of the
touchscreen, this value is perfect. However, when the screen
flickers, the value should be adjusted.
1. Start the calibration of the screen by clicking on the touchfield
button.
2. Use a fine pen to tap in the center of the 3 crosses shown in
order.
Touchfield
3. Press on the 4th cross and check if the value displayed next to it
is approximately 40 (X) and 200 (Y). If not, restart the calibration
by pressing key.
4. Press to save the calibration and new parameters when

done.
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Diagnostics mode
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Troubleshooting
Chapter 6 Troubleshooting
Important
6
 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. . . . . . . . . . . . . . . . . . . . . 122

 General troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
 Recoverable error messages with no error ID number . . . . . . . . . . . . . . . . . 126
Troubleshooting when an error is displayed . . . . . . . . . . . . . . . . . . . . . 128

 Errors with error number (ID 1009-6115) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
 Contourcutting errors and warnings (ID 6201-6271) . . . . . . . . . . . . . . . . . . . 131
 MGL errors (ID 4000-5000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
 BREVID_ERROR_HW_REVISION (6110-6120) . . . . . . . . . . . . . . . . . . . . . . 139
 FPGA ERRORS (6140 - 6150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
 RAM ERRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
 Other errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
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Troubleshooting
6.1 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
1 Connect power cable. -
2 Check wall outlet. -
3 Check if LED LD1G on the mainboard is lit green. Mainboard > LED summary on page 73
Media is present but does not start loading:
1 Lower the pressure roller lever -
2 Clean the media sensors. -
3 Check media sensors and lever sensor in diagnostics mode. Menu overview > Sensors on page 116
4 Check X-motor connection. X-motor and drive belt on page 33

J7 (X-motor and encoder) on page 72
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Troubleshooting
Data is sent from the PC but the cutting plotter does not react:
1 Connect the USB cable. ‐
2 Check if the Kona displays the ready message in the mainscreen. ‐
3 Try to send tests from the Mutoh CutServer. -
4 Reboot cutting plotter -
5 Reinstall USB drivers -
Parts of the design are not properly cut:
Cutting quality related problem:
1 Reload the media after the tool is set into the tool holder. -
2 Check or/and replace cutting blade -
3 Check if knife tip can still turn freely in the knife holder. Clean knife holder tip -
4 Check if the knife holder is mounted correctly. -
5 Check cutting force. 100gr is a good starting force. Force should never
-
exceed 140gr for cutting regular vinyl.
6 Check blade protrusion. Blade protrusion = vinyl thickness + glue layer. The
-
less the blade is cutting the backing the better the cutting quality
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Troubleshooting
7 Check cutting mat for unevenness and damage. If necessary replace the
-
cutting mat.
8 Slow down cutting speed. -
9 Perform offset calibration. -
10 Perform quality tests from Mutoh CutServer. Mutoh CutServer tests > Tracking test on page 100
11 Check parameter JOB FOCUS in user menu. Select ACCURACY instead of

-
SPEED.
12 Check X&Y belt tensions. X drive belt tension on page 86

Y drive belt tension on page 87
13 Perform Y-Z measurement in diagnostics mode. YZ profile on page 114
14 Check cutting head for play on UP/DOWN bearing. -
15 Replace X- and/or Y-motor. X-motor and drive belt on page 33

Y-motor on page 36
16 Replace mainboard. Electronics > Mainboard on page 67
17 Replace penhead assembly. Penhead assembly on page 44
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Troubleshooting
Media transport problems (tracking)
1 Clean grit rollers -
2 Clean pressure rollers. Replace if damaged. Pressure roller assembly on page 59
3 Use more pressure rollers if possible -
4 Pre-feed the media before every print job. -
5 Check position of both conveyer rolls. Parallel to the cutter? -
6 Slow down cutting speed -
7 Slow down "TOOL UP SPEED" in user menu -
8 Check parameter JOB FOCUS in user menu. Select ACCURACY instead of

-
SPEED.
9 Perform tracking tests via the Mutoh CutServer. Tracking test on page 100
10 Check pressure roll pressure. Mechanical adjustments on page 90
11 Replace grit shaft Grit shaft and support rollers on page 54
Note
 Media baskets can influence media tracking. Empty media baskets will avoid that media movement is disturbed. It is recommended
to disable (close) media baskets (front and back) in case of cutting lengths over 6 meter. In this case make sure the floor is clean
and assure enough space at the front and the rear of the plotter in order to let the media move freely in an out the cutting plotter.
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Troubleshooting
6.1.2 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.
Error Cause Solution

EPOS calibration error EPOS sensor goes in error during the 1. Try again or reboot and try again.
<RETRY> EPOS calibration. 2. Be sure that there is dark (not red) vinyl installed.
3. Test the EPOS sensor in Diagnostics mode
Refer to Menu overview > Actuators on page 115
4. Replace the EPOS sensor block if it does not work anymore.
Refer to Penhead assembly > EPOS sensor block on page 50
EPOS problem: PG When there has been executed a PG 1. Check the media size.
problem occurred command between 2 segments or at the 2. Reboot the machine.
start of a new job, this error can occur.
This can be caused by:
 Media is too short
 Job has been interrupted by the user
 A movement cannot be performed
because of mechanical failures.
The plot data is out of  The data sent to the cutter is larger 1. Load appropriate media.
limit and is clipped to than the position between the first 2. Reposition pressure rollers.
hardclip region and fourth pressure roller.
3. Redesign your job.
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Troubleshooting
Error Cause Solution

Unable to show point  There is an error during the switch 1. Try again or reboot and try again.
from the cutter knife to the laser or
vice versa.
 If the cutting head is located at the
end of a paper during the switch, this
error can occur also.
EPOS problem: No  It might be possible that the reference 1. Select the correct file in the Mutoh CutServer and start the job manually
EPOS reference found box cannot be found. (send EPOS job)
 The EPOS sensor is broken 2. Make sure that the printed reference box is made within the specifications.
(print the file once again with a thicker reference box, e.g. 5 mm or more)
3. Be sure that the contour cutting box is located in between the two outer
pressure rollers.
4. Be sure that the media is loaded straight.
5. Test the EPOS sensor in Diagnostics mode
Refer to Menu overview > Actuators on page 115
6. Replace the EPOS sensor block if it does not work anymore.
Refer to Penhead assembly > EPOS sensor block on page 50
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Troubleshooting
6.2 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 anymore. Because of a media crash or
from moving and restart the cutter. error
mechanical obstruction for example.
The media can not be fed forward/backward.
Remove the media or object blocking the grit Fatal
1010 X position error Because of a media crash, too heavy media or
rolls from moving and restart the cutter. error
mechanical obstruction.
 X fuse is broken 1. Check/replace fuse FU1
 X motor problem Refer to Electronics > Mainboard on page 73
 Mainboard driver problem
Refer to X and Y motor fuse on page 74
Fatal
1014 X fuse error 2. Check/replace the X-motor
error
Refer to X-motor and drive belt on page 33
3. Check/replace the mainboard
Refer to Electronics > Mainboard on page 67
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Troubleshooting

 Y fuse is broken 1. 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 2. Check/replace the Y-motor
error
Refer to Y-motor on page 36
3. Check/replace the mainboard
 Z encoder or flatcable is broken 1. Check/replace the penhead flatcable
Refer to Penhead FFC (flexible flat cable) on
page 41
2. Check/replace the penhead PCB
Refer to Penhead PCB on page 75 Fatal
1045 No Z encoder
error
3. Replace the penhead assembly
Refer to Penhead assembly on page 44
4. Replace the mainboard
Refer to Mainboard on page 67
There is too much force necessary to move the Remove the media or object blocking the head Fatal
1049 Y PWM max error
head left or right. from moving and restart the cutter. error
There is too much force necessary to move the Remove the media or object blocking the grit Fatal
1050 X PWM max error
media back- and/or forwards. rolls from moving and restart the cutter. error
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Troubleshooting

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
1. Make sure that the difference between white
and color can be recognized by the EPOS
sensor
6098 EPOS calibration error Could not calibrate the pen to laser distance 2. The media has not been weed out (when Warning
asked on the display) before the EPOS
alignment measurement
3. The laser is broken.
EPOS measurement is There is too much variation between the X and 1. Is the media loaded correctly?
6099 Warning
unstable Y calibration measurements
The cutter can not finish the cutter width
Bump problem machine Remove the media or object blocking the head
6100 measurement routine. This could be caused by Warning
width from moving and restart the cutter.
a mechanical obstruction.
X measurement problem. The rear media sensor is uncovered during a 1. Try tIs the media loaded correctly?
6105 Warning
Reload media media measurement routine
1. Check/replace the touchscreen flatcable
TFT board detection The flatcable of the touch screen is not Refer to Touchscreen on page 80
6115 Warning
problem connected or broken 2. Check/replace the mainboard
Refer to Mainboard on page 67
130 AP-74380 - Revision 1.1

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.
Pre-defined crosses Single frame calibration points Multi frame calibration points
P7 P6
5
P8 P5
P7 P6
last segment
3 P8 P5
4 P10 P9
2
1
P12 P11
middle segments
P10 P9
P12 P11
1. Print distortion - Bad rectangle
2. Media shift detected P4 P1 1st segment
3. Print distortion - Stretch

P3 P2
4. Possible data clipped P4 P1
5. Thickness problem P3 P2
131 AP-74380 - Revision 1.1

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.
 An error means that you will have to retry the scanning routine. The reading of the frame has been cancelled.

6201 EPOS alignment aborted EPOS alignment aborted
6202 EPOS alignment aborted The pressure rollers are raised - Error
6203 EPOS alignment aborted Alignment procedure has been aborted by the user
6206 Movement failed Movement failed during EPOS routine (moveabsc)
6207 Movement failed Movement failed during EPOS routine (drawcontrol) - Error
6208 Movement failed Movement failed during EPOS routine (scanroutine)
6211 Barcode problem occurred Barcode too long
6212 Barcode problem occurred Barcode width problem Rescan the job and if the error still
6213 Barcode problem occurred Barcode height problem occurs, try to:
Error
6214 Barcode problem occurred Barcode scan problem 1 (lower line of barcode)  Replot the job
6215 Barcode problem occurred Barcode scan problem 2 (upper line of barcode)  Reprint the job
6216 Barcode problem occurred Checksum not OK
Check if the margins left, right, top and bottom are within
6218 Media size problem the specifications.  Did you sent the correct file Error
It might be possible that the file you have sent is not correct
6221 Page problem occurred PG after job failed
PG between 2 segments failed or the cutter is set to repeat Check the media size Error
6222 Page problem occurred
mode and there cannot be found a next job.
During search with EPOS laser, no edge was found 
6223 No EPOS reference found - Error
(colour <> white)
132 AP-74380 - Revision 1.1

Troubleshooting

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. Warning
bad rectangle sides (difference > 3mm)
Stretch detected on bottom of frame. P1 & P4 have identical
Print distortion thickness. P2 & P3 have identical thickness. But thickness
6227
print stretch of P1-P4 and P2-P3 differ too much from each other. Print
is stretched.
Stretch detected on top of frame. P5 & P8 have identical
Print distortion thickness. P6 & P7 have identical thickness. But thickness You can try to cut the job if you want
6228
print stretch of P5-P8 and P6-P7 differ too much from each other. Frame to. Perfect quality is not
(print result) is stretched. guaranteed. What to check in case
Stretch detected on side of frame. Px & Py have identical of bad quality:
Warning
thickness. Pw & Pz have identical thickness. But thickness  Printer settings
of Px-Py and Pw-Pz differ too much from each other. Frame
 RIP settings
(print result) is stretched! Depending on kind of measured
Print distortion segment: Px, Py, Pw, Pz are different.  Design
6229
print stretch 1. Px = P1, Py = P4, Pw = P5, Pz = P8
2. Px = P1, Py = P4, Pw = P9, Pz = P10
3. Px = P9, Py = P10, Pw = P11, Pz = P12
4. Px = P11, Py = P12, Pw = P5, Pz = P8
133 AP-74380 - Revision 1.1

Troubleshooting

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
6232 Thickness varies too much from other bottom points! This
frame bottom
will influence the accuracy of the cutting.
Invalid thickness of P2 (bottom right of frame bottom).
6233 Thickness varies too much from other bottom points! This You can try to cut the job if you want
frame bottom
will influence the accuracy of the cutting. to. Perfect quality is not
Invalid thickness of P3 (bottom left side of frame bottom). guaranteed. What to check in case
6234 Thickness varies too much from other bottom points! This of bad quality:
frame bottom Warning
will influence the accuracy of the cutting.  Printer settings
Invalid thickness of P4 (left side of bottom point). Thickness RIP settings
Thickness problem 
6235 varies too much from other bottom points! This will
frame bottom  Design
influence the accuracy of the cutting.
Invalid thickness of P1 and P4. Thickness of these points
6236 varies too much from each other AND varies also from P2 &
frame bottom
P3! This will influence the accuracy of the cutting.
frame bottom
134 AP-74380 - Revision 1.1

Troubleshooting

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
6242 varies too much from other top points! This will influence the
frame top
accuracy of the cutting.
Invalid thickness of P6 (top right of frame top). Thickness
6243 varies too much from other top points! This will influence the You can try to cut the job if you want
frame top
accuracy of the cutting. to. Perfect quality is not
Invalid thickness of P7 (top left side of frame top). guaranteed. What to check in case
6244 Thickness varies too much from other top points! This will of bad quality:
frame top Warning
influence the accuracy of the cutting.  Printer settings
Invalid thickness of P8 (left side of top point). Thickness RIP settings
Thickness problem 
6245 varies too much from other top points! This will influence the
frame top  Design
accuracy of the cutting.
frame top
frame top
135 AP-74380 - Revision 1.1

Troubleshooting

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
6252 too much from P10! This will influence the accuracy of the
frame centre
cutting.
Invalid thickness of P10 (left centre point). Thickness varies You can try to cut the job if you want
Thickness problem to. Perfect quality is not
frame centre guaranteed. What to check in case
cutting.
of bad quality:
Thickness of centre points (P11 & P12) differs too much Warning
Thickness problem  Printer settings
6254 from each other AND differs also from bottom points P1 and
frame centre
P4.  RIP settings
Invalid thickness of P11 (right centre point). Thickness  Design
6255 varies too much from P12! This will influence the accuracy
frame centre
of the cutting.
Invalid thickness of P12(left centre point). Thickness varies
frame centre
cutting.
136 AP-74380 - Revision 1.1

Troubleshooting

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.  Frame isn't found within 120 cm.
6263 No valid frame found No frame points found during diagonal scan. Media space before frame
bottom is too much.
6264 No valid frame found Thickness of left side of frame invalid
 Frame bottom doesn't have the Error
6265 No valid frame found Varying thickness correct specifications (minimum
6266 No valid frame found Invalid thickness thickness of 3mm on ALL sides,
6267 No valid frame found Invalid frame angle thickness too varying, frame
height < 20cm, frame width <
6268 No valid frame found Requested X movement for fast scan cannot be executed. 10cm, frame angle < 5°)
6269 No valid frame found Invalid spot type
To check:
Media displacement detected during cutting. Centre
6271 Media shift detected  Grits on media? Warning
markers of previous segment are shift more than 2mm.
 Pinches and grits clean?
137 AP-74380 - Revision 1.1

Troubleshooting
6.2.3 MGL errors (ID 4000-5000)
As from the moment data is sent to the Kona which is not correct, an error and sub error number will be displayed. Please find below a list with
explanations of these sub numbers.
Error screen Sub number Description

0 No parameters allowed
1 No parameter case is illegal
2 Not enough parameters
3 Too many parameters
4 Illegal command termination
5 Illegal command definition
6 Undefined program flow
7 Parameter size overflow
8 Error in HPGL command definition
9 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.
138 AP-74380 - Revision 1.1

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 > Download latest software and drivers on page 94
Old revision board for a new firmware version Install a compatible firmware version
Refer to Software and drivers > Download latest software and drivers on page 94
139 AP-74380 - Revision 1.1

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

140 AP-74380 - Revision 1.1

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. 6
Troubleshooting
The mainboard should be replaced

AP-74380 - Revision 1.1 141

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
N
Problem
solved?
Y
Restore parameters
Problem N
Reset to factory defaults
solved?
Y
Problem N
DONE
solved?
Y
Peform following
adjustments
1. XY accuracy calibration
2. EPOS calibration
3. Pen force calibration
4. YZ profile calibration
5. Touchscreen calibration
Problem N
solved?
Y
DONE Replace mainboard
142 AP-74380 - Revision 1.1

Index
A E
Accuracy menu . . . . . . . . . . . . . . . . . . . . . . 113 Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Mainboard . . . . . . . . . . . . . . . . . . . . . . . . 67
Actuators menu . . . . . . . . . . . . . . . . . . . . . . 115
Penhead PCB . . . . . . . . . . . . . . . . . . . . . 75
Adjustements Power supply . . . . . . . . . . . . . . . . . . . . . . 78
Mechanical . . . . . . . . . . . . . . . . . . . . . . . 86 Touchscreen . . . . . . . . . . . . . . . . . . . . . . 80
Adjustment procedures . . . . . . . . . . . . . . . . . 85 Encoder menu . . . . . . . . . . . . . . . . . . . . . . . 110
Penhead drive belt tension . . . . . . . . . . . 88
EPOS
Pressure roller pressure . . . . . . . . . . . . . 90
Calibration procedure . . . . . . . . . . . . . . . 103
Sheeting-off knife position . . . . . . . . . . . . 91
Sensor block replacement . . . . . . . . . . . . 50
X drive belt tension . . . . . . . . . . . . . . . . . 86
Y drive belt tension . . . . . . . . . . . . . . . . . 87 Error handling . . . . . . . . . . . . . . . . . . . . . . . . 121
Aging menu . . . . . . . . . . . . . . . . . . . . . . . . . 117 Errors
Contourcutting errors . . . . . . . . . . . . . . . 131
Ambient conditions . . . . . . . . . . . . . . . . . . . . . 14
FPGA Errors . . . . . . . . . . . . . . . . . . . . . . 140
ID 1009-6115 . . . . . . . . . . . . . . . . . . . . . 128
B ID 4000-5000 . . . . . . . . . . . . . . . . . . . . . 138
ID 6110-6120 . . . . . . . . . . . . . . . . . . . . . 139
Backup parameters . . . . . . . . . . . . . . . . . . . . 98 ID 6140 - 6150 . . . . . . . . . . . . . . . . . . . . 140
ID 6201-6271 . . . . . . . . . . . . . . . . . . . . . 131
Board diagnostics MGL errors . . . . . . . . . . . . . . . . . . . . . . . 138
Mainboard . . . . . . . . . . . . . . . . . . . . . . . . 70 Others . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Penhead PCB . . . . . . . . . . . . . . . . . . . . . 76 Ram Errors . . . . . . . . . . . . . . . . . . . . . . . 141
With ID number . . . . . . . . . . . . . . . . . . . 126
C Without ID number . . . . . . . . . . . . . . . . . 122
Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . 85 F
Connection menu . . . . . . . . . . . . . . . . . . . . . 109
Firmware . . . . . . . . . . . . . . . . . . . . . . . . . 85, 94
Covers Installation procedure . . . . . . . . . . . . . . . . 94
Penhead cover removal . . . . . . . . . . . . . . 30 Where to download . . . . . . . . . . . . . . . . . 94
Y-rail cover removal . . . . . . . . . . . . . . . . . 29
FPGA Errors . . . . . . . . . . . . . . . . . . . . . . . . . 140
D Front platen removal procedure, Covers

Front platen removal . . . . . . . . . . . . . . . . 31
Defaults menu . . . . . . . . . . . . . . . . . . . . . . . 112 Fuse
Diagnostics X and Y motor . . . . . . . . . . . . . . . . . . . . . 74
Menu overview . . . . . . . . . . . . . . . . . . . . 23
Diagnostics mode . . . . . . . . . . . . . . . . . . . . 105 G
Diagnostics 1 . . . . . . . . . . . . . . . . . . . . . 106
Diagnostics 2 . . . . . . . . . . . . . . . . . . . . . 107 Grit shaft
How to start up in diagnostics . . . . . . . . 106 Exploded view . . . . . . . . . . . . . . . . . . . . . 53
Menu overview . . . . . . . . . . . . . . . . . . . 108 Replacment procedure . . . . . . . . . . . . . . . 54
Support rollers replacement procedure . . 54
Dimensions machine . . . . . . . . . . . . . . . . . . . 14
AP-74380 - Revision 1.1 I

I P
Install the USB drivers . . . . . . . . . . . . . . . . . . 97 Paper sensor
Front/middle sensor replacement . . . . . . . 82
Installation environment . . . . . . . . . . . . . . . . . 14
Rear sensor replacement . . . . . . . . . . . . . 82
Ambient conditions . . . . . . . . . . . . . . . . . 14
Power supply . . . . . . . . . . . . . . . . . . . . . . 14 Parameters . . . . . . . . . . . . . . . . . . . . . . . 85, 98
Room conditions . . . . . . . . . . . . . . . . . . . 15 Backup procedure . . . . . . . . . . . . . . . . . . 98
Restore procedure . . . . . . . . . . . . . . . . . . 99
M Part names and functions . . . . . . . . . . . . . . . . 16
Part replacement procedures . . . . . . . . . . . . . 25
Mainboard
Board diagnostics . . . . . . . . . . . . . . . . . . 70 Penhead assembly
replacement procedure . . . . . . . . . . . . . . 67 EPOS sensor block replacement . . . . . . . 50
Exploded view . . . . . . . . . . . . . . . . . . . . . 40
Menu overview . . . . . . . . . . . . . . . . . . . . . . . . 20 Penhead drive belt replacement . . . . . . . 47
Diagnostics mode 1 and 2 . . . . . . . . . . . . 23 Penhead flatcable replacement procedure .
Tree diagram . . . . . . . . . . . . . . . . . . . . . . 20 41
User mode . . . . . . . . . . . . . . . . . . . . . . . . 20 Sheet-off mechanism replacement . . . . . 49
MGL errors (ID 4000-5000) . . . . . . . . . . . . . 138 Y-origin flex PCB . . . . . . . . . . . . . . . . . . . 52
Mutoh CUTserver tests . . . . . . . . . . . . . . . . 100 Penhead cover removal procedure . . . . . . . . . 30

Tracking test . . . . . . . . . . . . . . . . . . . . . 100 Penhead drive belt
XY-distance accuracy test . . . . . . . . . . . 102 Replacement procedure . . . . . . . . . . . . . . 47
Tension adjustment . . . . . . . . . . . . . . . . . 88
O Penhead flatcable
Replacement procedure . . . . . . . . . . . . . . 41
Operation panel
Main menu . . . . . . . . . . . . . . . . . . . . . . . . 17 Penhead PCB
Settings or actions menu . . . . . . . . . . . . . 18 Board diagnostics . . . . . . . . . . . . . . . . . . . 76
Power requirements . . . . . . . . . . . . . . . . . . . . 14
Power supply
replacement procedure . . . . . . . . . . . . . . 78
Pressure roller
Assembly replacement procedure . . . . . . 61
Exploded view . . . . . . . . . . . . . . . . . . . . . 59
Lever sensor replacement . . . . . . . . . . . . 81
Pressure adjustement . . . . . . . . . . . . . . . 90
Product overview . . . . . . . . . . . . . . . . . . . . . . 13
Part names and functions . . . . . . . . . . . . 16
PWM test menu . . . . . . . . . . . . . . . . . . . . . . 111
II AP-74380 - Revision 1.1

R U
RAM errros . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Uninstall the USB drivers . . . . . . . . . . . . . . . . 96
Rear platen removal procedure, Covers USB drivers
Rear platen removal . . . . . . . . . . . . . . . . 32 Installation procedure . . . . . . . . . . . . . . . . 97
Uninstallation procedure . . . . . . . . . . . . . 96
Regulations ........................... 9
Restore parameters . . . . . . . . . . . . . . . . . . . . 99
V
S Vacuum fan replacement procedure . . . . . . . . 83
Safety
General information . . . . . . . . . . . . . . . . . . 9 X
Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
X drive belt
Screen menu . . . . . . . . . . . . . . . . . . . . . . . . 119 Replacement procedure . . . . . . . . . . . . . . 33
Sensors Tension adjustment . . . . . . . . . . . . . . . . . 86
Front/middle sensor replacement . . . . . . 82 X-motor
Pressure roller lever sensor replacement 81 Fuse replacement . . . . . . . . . . . . . . . . . . 74
Rear sensor replacement . . . . . . . . . . . . 82 Replacement procedure . . . . . . . . . . . . . . 33
Replacement procedures . . . . . . . . . . . . 81
XY-distance accuracy test . . . . . . . . . . . . . . 102
Sensors menu . . . . . . . . . . . . . . . . . . . . . . . 116
Sheeting-off knife Y
Position adjustement . . . . . . . . . . . . . . . . 91
Sheet-off mechanism Y drive belt
Replacement procedure . . . . . . . . . . . . . 49 Tension adjustment . . . . . . . . . . . . . . . . . 87
Side covers removal procedure, Covers Y-drive pulley

Side covers removal . . . . . . . . . . . . . . . . 28 Replacement procedure . . . . . . . . . . . . . . 38
Software . . . . . . . . . . . . . . . . . . . . . . . . . .85, 94 Y-motor

Where to download . . . . . . . . . . . . . . . . . 94 Exploded view . . . . . . . . . . . . . . . . . . . . . 35
Fuse replacement . . . . . . . . . . . . . . . . . . 74
Space necessary . . . . . . . . . . . . . . . . . . . . . . 15 Replacement procedure . . . . . . . . . . . . . . 36
Speed reduction belt Y-origin flex PCB
Replacement procedure . . . . . . . . . . . . . 38 Replacement procedure . . . . . . . . . . . . . . 52
Y-rail cover removal procedure . . . . . . . . . . . . 29
T
Y-return pulley
Tool Force menu . . . . . . . . . . . . . . . . . . . . . 115 Replacement procedure . . . . . . . . . . . . . . 39
Touchscreen YZ measurement . . . . . . . . . . . . . . . . . . . . . . 93
replacement procedure . . . . . . . . . . . . . . 80 YZ profile menu . . . . . . . . . . . . . . . . . . . . . . 114
Tracking test . . . . . . . . . . . . . . . . . . . . . . . . 100
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 121
Recoverable errors . . . . . . . . . . . . . . . . 126
When no error is displayed . . . . . . . . . . 122
AP-74380 - Revision 1.1 III

IV AP-74380 - Revision 1.1

Service Manual Kona - Rev 1.1

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AP-74380 - Revision 1.0 3

Parts replacement summary

Please find below an overview:

1. Pen head replacement page 44

2. Mainboard replacement page 67

3. Y-motor or Y speed reduction belt replacement page 35

4. X-motor replacement page 33

5. Pressure roller assembly replacement page 61

4 AP-74380 - Revision 1.0

1.1 Warnings, cautions and notes . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.2 Compliance with the following regulations . . . . . . . . . . . . . . 10

1.3 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.4 Safety labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 2 Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1 Dimensions machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.2 Installation environment requirements . . . . . . . . . . . . . . . . . . 14

2.3 Part names and functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.4 Overview operation panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.5 Menu overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.6 Machine version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

AP-74380 - Revision 1.0 5

Chapter 3 Part replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.1 Cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.2 X-motor and drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.3 Y-motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.4 Penhead assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.5 Grit shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3.6 Pressure roller assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

3.7 Cutting mat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

6 AP-74380 - Revision 1.0

Chapter 4 Adjustments and calibrations . . . . . . . . . . . . . . . . . 85

4.1 Mechanical adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

4.2 Software and drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

4.4 Mutoh CutServer tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

4.5 EPOS calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

AP-74380 - Revision 1.0 7

Chapter 5 Diagnostics mode . . . . . . . . . . . . . . . . . . . . . . . . . . 105

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

5.2 How to start up in diagnostics mode 1 and 2 . . . . . . . . . . . . 106

5.3 Menu overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Chapter 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

6.1 Troubleshooting when no error is displayed . . . . . . . . . . . . 122

6.2 Troubleshooting when an error is displayed . . . . . . . . . . . . 128

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Regulations and safety information

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Regulations and safety information

1.1 Warnings, cautions and notes

Safety terms Details

1.2 Compliance with the following regulations

By affixing the CE marking, the manufacturer, his authorized

This product is tested and approved by the Canadian Standards

The product is tested according to IEC60950.

CSA International certification is not a legal commitment but it

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Regulations and safety information

Your product is designed and manufactured with high-quality

When this crossed-out wheeled bin submenu is attached to a

ICES This Class A digital apparatus complies with Canadian ICES-003.

1.3 Important notes

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