MUTOH Kona 760 User manual

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

Service manual Kona cutting plotter
AP-74380 - Revision 1.0 3
Copyright notice
COPYRIGHT © 27/4/10 Mutoh Europe nv All rights reserved.
Mutoh Europe nv reserves the right to modify the information contained in this manual at any
time without prior notice.
This document may not be reproduced by any means, in whole or in part, without written
permission of the copyright owner.
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.

Service manual Kona cutting plotter
4AP-74380 - Revision 1.0
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

Service manual Kona cutting plotter
AP-74380 - Revision 1.0 5
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

Service manual Kona cutting plotter
6AP-74380 - Revision 1.0
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

Service manual Kona cutting plotter
AP-74380 - Revision 1.0 7
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

Service manual Kona cutting plotter
8AP-74380 - Revision 1.0
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

1
Service manual Kona cutting plotter
Regulations and safety information
AP-74380 - Revision 1.1 9
Chapter1Regulationsand
safetyinformation
Warnings, cautions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Compliance with the following regulations . . . . . . . . . . . . . . . . . . . . . . . 10
Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Service manual Kona cutting plotter
Regulations and safety information
10 AP-74380 - Revision 1.1
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.
1.2 Compliance with the following regulations
Safety terms Details
Important Must be followed carefully to avoid death or serious bodily injury.
Caution Must be observed to avoid bodily injury (moderate or light) or damage to
your equipment.
Notes Contains important information and useful tips on the operation of your
cutter.
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.