Ultima MM

Maintenance Manual
ULTIMA
CUTTING PLOTTER
MUTOH EUROPE N.V. AP-74050, Rev.: 1.1

2 AP-74050, Rev : 1.1
COPYRIGHT NOTICE
COPYRIGHT © 2003 Mutoh Europe N.V. all rights reserved.
This document may not be reproduced by means, in whole or in part, without written permission of the
copyright owner.
This document is furnished to support the Mutoh Ultima Multi-purpose cutting plotter (SC-850D and SC-
1400D). In consideration of the furnishing of the information contained in this document, the party to whom it
is given assumes its custody and control and agrees to the following :
The information herein contained is given in confidence, and any part thereof shall not be copied or
reproduced without written consent of Mutoh Europe N.V.
This document or the contents herein under no circumstances, shall be used in the manufacture or
reproduction of the article shown and delivery of this document shall not constitute any right or license to do
so.
March 2003
Published: Mutoh Europe N.V., Archimedesstraat 13, B-8400 Oostende, BELGIUM
FCC WARNING
This equipment complies with the requirements for a class A computing device in the FCC rules, part 15,
subpart J.
Operation of this device in a residential area may interfere with television or operating utilities.
Cutters generate weak radio signals and may interfere with television reception and utilities. If the cutter
does interfere with radio or TV reception, try the following :
Change the direction of your radio and TV reception antenna or feeder.
Change the direction of the cutter.
Move either the cutter or the receiving antenna so that there is more distance between them.
Be sure the cutter and the receiving antenna are on separate power lines.
.
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4 AP-74050, Rev : 1.1
TABLE OF CONTENTS
1. SPECIFICATIONS..........................................................................................................................9
1.1. EMC statement for CE Marking ...............................................................................................9
1.2. Important note ...........................................................................................................................9
1.3. Specifications of the Ultima Cutting Plotter ...........................................................................10
1.4. Ultima cutting plotter, environment........................................................................................11
1.5. Function keys ..........................................................................................................................12
2. SYSTEM BLOCK DIAGRAM .....................................................................................................15

2.1. Block diagram SC-850D.........................................................................................................15
2.2. Block diagram SC-1400D.......................................................................................................16
3. INTERFACES ...............................................................................................................................17
3.1. Serial interface RS-232C (standard) .......................................................................................17
3.1.1. RS-232 pin configuration.................................................................................................18
3.1.2. Serial cable configuration ................................................................................................18
3.2. USB interface..........................................................................................................................19
3.2.1. USB pin configuration .....................................................................................................19
4. TROUBLESHOOTING.................................................................................................................21
4.1. Recoverable errors ..................................................................................................................21
4.2. Unrecoverable errors...............................................................................................................22
4.3. Problem symptoms and suggested actions..............................................................................23
4.3.1. Processor errors................................................................................................................23
4.3.4. E-pos errors ......................................................................................................................24
4.3.5. Other errors ......................................................................................................................24
5. DIAGNOSTIC Mode.....................................................................................................................27
5.1. How to get in Diagnostic Mode? ............................................................................................27
5.2. How to leave in Diagnostic Mode?.........................................................................................27
5.3 Diagnostic Menu – menu overview .........................................................................................28
5.3.1 Factory default ..................................................................................................................28
5.3.2 EPOS readout....................................................................................................................29
5.3.3 Setting plot ........................................................................................................................30
5.3.4 Serial Number ...................................................................................................................31
5.3.5 Robot 2 test .......................................................................................................................32
5.3.6 Set Accuracy .....................................................................................................................33
5.3.7 Robot 1 test .......................................................................................................................34
5.3.8 Calibrate E-pos..................................................................................................................35
5.3.9 Measure Y .........................................................................................................................39
5.3.10 Penforce check ................................................................................................................40
5.3.11 Panel test 2 ......................................................................................................................41
5.3.12 Panel test 1 ......................................................................................................................42
5.3.13 Actuator write .................................................................................................................43
5.3.14 Sensor readout.................................................................................................................44
5.3.15 Quality Test.....................................................................................................................45
5.3.16 Update firmware keyboard..............................................................................................46
5.3.17 Aging...............................................................................................................................47
5 AP-74050, Rev : 1.1

5.4 Diagnostic mode – Error ..........................................................................................................48
5.4.1 How to get in diagnostic mode. ........................................................................................48
5.4.2 How to leave diagnostic mode ..........................................................................................48
5.5 Ultima shortcut key combinations. ..........................................................................................49
6. PARTS REPLACEMENT AND ADJUSTMENT ........................................................................51

6.1. Maintenance access table for parts replacement .....................................................................51
6.2. Mechanical parts .....................................................................................................................52
6.2.1. Covers Left : removal and installation.............................................................................52
6.2.2. Cover Right : removal and installation ............................................................................53
6.2.3. PCB box: open and close .................................................................................................54
6.2.4. Keyboard: removal and installation .................................................................................55
6.2.5. Y-rail Cover : removal and installation............................................................................55
6.2.6. Front Paper Sensor : removal and installation .................................................................55
6.2.7. Rear Paper Sensor : removal and installation ..................................................................56
6.2.8. Cutting Head : removal and installation ..........................................................................56
6.2.9. Grid Rollers : removal and installation ............................................................................58
6.2.10. Y-drive belt (long) : removal and installation................................................................59
6.2.9. Pressure roller pressure adjustment..................................................................................62
6.3. Electronical parts.....................................................................................................................63
6.3.1. Main PC board : removal and installation .......................................................................63
6.3.2. Head board installation ....................................................................................................65
6.3.3. Power supply board : removal and installation................................................................66
6.3.4. Power supply output connections ....................................................................................66
6.3.5. X-motor and drive belt : removal and installation ...........................................................67
6.3.6. Y-motor and drive belt : removal and installation ...........................................................68
6.3.7. Head flex cable : removal and installation.......................................................................69
6.3.8. Pressure roller UP/DOWN sensor : removal and installation..........................................70
6.3.9. Fan motors : removal and installation..............................................................................71
6.4. How to correctly install new firmware ...................................................................................72
6.4.1. Installation of new firmware with the USB cable............................................................72
6.4.2. Installation of new firmware with the serial cable...........................................................74
6.4.3. Installation of new firmware a flash card.........................................................................75
6.5. Performing a code update .......................................................................................................76
6.6. When you shut down the Ultima outside the critical section..................................................77
6.7. When you shut down the Ultima inside the critical section....................................................79
6.8. How to perform a parameter backup.......................................................................................80
6.8.1. Saving the settings onto the parameter backup card ........................................................80
6.8.2. Saving the settings from the parameter backup card onto the board ...............................81
6.9 Offset adjustment .....................................................................................................................82
7. JIG TOOL LIST.............................................................................................................................83

7.1. Jig tool list...............................................................................................................................83
7.2. Special glue .............................................................................................................................83
8. PARTS LISTS Ultima ...................................................................................................................85

8.1. Body and Covers.....................................................................................................................85
8.2. Keyboard Assy........................................................................................................................86
8.3. Aging Level.............................................................................................................................87
8.4. Penhead Assy ..........................................................................................................................88
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8.5. Cutter holder assy....................................................................................................................89
8.6. Laser-Epos Assy Penhead.......................................................................................................90
8.7. Base plate assy ........................................................................................................................91
8.8. Base assy .................................................................................................................................92
8.9. Mechanicals final assy ............................................................................................................93
8.10. Suction tube assy...................................................................................................................94
8.11. Lever assy .............................................................................................................................95
8.12. XY-motor assy ......................................................................................................................96
8.13. Belt-cam ................................................................................................................................97
8.14. Y-drive pulley .......................................................................................................................98
8.15. Y-return pulley assy ..............................................................................................................99
8.16. X-motor pulley assy ............................................................................................................100
8.17. Y-motor pulley assy ............................................................................................................101
8.18. XY assy ...............................................................................................................................102
8.19. X-rail assy ...........................................................................................................................103
8.20. Bearing holder assy.............................................................................................................104
8.21. Y-rail assy ...........................................................................................................................105
8.22. Pressure Roller assy ............................................................................................................106
8.23. Paper sensors assy...............................................................................................................107
8.24. Left end plate assy...............................................................................................................108
8.25. Right end plate assy ............................................................................................................109
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8 AP-74050, Rev : 1.1
Maintenance Manual – Ultima Cutting Plotter
1. SPECIFICATIONS
1.1. EMC STATEMENT FOR CE MARKING
Important :
• This is a Class A product approved for industrial environments. In a domestic

environment this product may cause radio interference in which case you may
be required to take adequate measures.
1.2. IMPORTANT NOTE

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.
Important :
• Details of this product and this manual are protected by copyright held by
this company and except for legitimate use by individuals, may not be
copied, reproduced or distributed in whole or in part.
• Details contained in this manual may be subject to future alteration without
notice.
• Details contained in this manual are believed to be correct but please contact
this company or your dealer if you suspect an error or if a point is not clear.
• In no event will this company be responsible for the consequences of using
this product or this manual.
9 AP-74050, Rev : 1.1

1.3. SPECIFICATIONS OF THE ULTIMA CUTTING PLOTTER
Specifications ULTIMA SC-850D ULTIMA SC-1400D

Max. Media Width 850 (roll & sheet) 1400 (roll & sheet)
Cutting Range 100-630 (Left border 10 mm/ right 100-1200 (Left border 10 mm/ right
border 10 mm) border 10 mm)
Max. Media Thickness 1.0 mm
Applicable Tool Cutter / ink pen / ball point / ceramic / fibre / pressurised ball point
Drive Mechanism Friction
Cutting Principle Drag
Mechanical Resolution 0.005 mm
Accuracy 0.15 % of distance moved or ± 0.25 mm (whichever is greater)
Repeatability (mm/m) 0.25 0.25
No. of Pressure Rollers 2 3
Knives 30° / 45° / 60°
Speed 100 – 1000 mm/s axial (1414 mm/s diagonal)
Acceleration Max. 3 G (tool up & down) / Automatic control, speed linked to media width
Tool Up / Down Cycles 40 per second
Cutting Force Range 20 – 450 g (stepwise adjustable)
Interface (standard) RS-232 & USB
Input Buffer (standard) 6 MB
Roll support system + Media Standard (included)
collection basket
Automatic Take-up system Optional
Graphic language MH-GL/2 (HP-GL/2 compatible)
Configurable Origin Yes
Offset adjustment Yes (0 – 1 mm)
Auto Sheet Off Function + Yes
Replot Function
Alignment Feature for Integrated Laser-Alignment Tool
contour cutting
Keyboard with LCD-Display Detachable with 4 lines, 16 character/line LCD
Power requirements AC 100/120 V, AC 220/240 V
10 AP-74050, Rev : 1.1

1.4. ULTIMA CUTTING PLOTTER, ENVIRONMENT
The location where you set up your equipment is very important. Please see to it that it meets following
conditions :
• Power supply of 100 to 120 VAC 50/60 Hz or 200 to 240 VAC 50/60 Hz.
• Ambient conditions :
o Operating environment
Temperature : 5 °C to 30 °C
Humidity : 35 % - 75 % non-condensation
o Recommended environment
Temperature : room temperature 16 °C to 25 °C
Humidity : 50 % to 65 % non-condensation
o Variation rate
Temperature : 2 °C per hour
Humidity : 5 % per hour
o Storage environment
Temperature : 0 °C to 50 °C
• Please protect your cutter from moisture, dust, draughts and direct sunlight. 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.
• Avoid unnecessary vibrations and set up your cutter on a level surface.
• When selecting a place for your cutter, leave at least 90 cm in front and 90 cm at the rear.
11 AP-74050, Rev : 1.1

1.5. FUNCTION KEYS

Using the control panel, you can access different modes and alter several settings, in order to fine-tune the
cutter to match all your needs.
1) CANCEL : The [CANCEL] key is controlling the cancel function. By pressing the
[CANCEL] key, instead of confirmation you will keep the previous setting.
By pressing the [CANCEL] key you can clear all received data.
2) EXIT : The [EXIT] key cancels the changes made in the setting. You will return
to the previous menu.
Press the [EXIT] key in normal mode to perform a shut off.
3) ENTER : Press the [ENTER] key to select a menu.
Press the [ENTER] key to confirm the changes made to the setting.
4) READY / PAUSE : Press the [READY/PAUSE] key to set the cutter “READY or PAUSE”
5) UP : Press the [UP] key to increase the value of the setting.

Press the [UP] key to select a parameter in the menu.
6) DOWN : Press the [DOWN] key to decrease the value of the setting.
Press the [DOWN] key to select a parameter in the menu.
7) PRESETS : Change the user (there are maximum 32 users), each user has his own
set of settings, that are saved when the machine is shut down.
8) ORIGIN : Press the [ORIGIN] key to change the origin.
9) TEST : Press the [TEST] key to choose one of the testplots to plot.
10) CONTOUR CUTTING : Press the [CONTOUR CUTTING] key to start an auto/manual aligning
procedure.
11) SPEED : Press the [SPEED] key to change the value of the speed.
12) FORCE : Press the [FORCE] key to change the value of the force.
12 AP-74050, Rev : 1.1

13) OFFSET : Press the [OFFSET] key to change the value of the offset.
14) TOOL : Press the [TOOL] key to change the tool type.
15) Take-up / Sheet / Roll : Press the [TUSR] key to select the loaded media.
16) ARROW-KEY : Press the [ARROW] key for manual movement of the tool head.
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14 AP-74050, Rev : 1.1

2. SYSTEM BLOCK DIAGRAM
2.1. BLOCK DIAGRAM SC-850D
15 AP-74050, Rev : 1.1

2.2. BLOCK DIAGRAM SC-1400D
16 AP-74050, Rev : 1.1

3. INTERFACES
3.1. SERIAL INTERFACE RS-232C (STANDARD)
1) Baud rate (software selectable)
• 9600 bps
• 4800 bps
• 2400 bps
• 1200 bps
2) Data length (software selectable)
• 7 bits
• 8 bits
3) Stop bits (software selectable)
• 1 bit
• 2 bits
4) Parity (software selectable)
• Odd
• Even
• None
5) Error detection
• Parity error
• Framing error
• Overrun error
6) External connector
• DB-9F
7) RS-232C driver / receiver IC
• HIN 238CP
17 AP-74050, Rev : 1.1

3.1.1. RS-232 pin configuration
PIN # SIGNAL Abbr. Signal direction

2 Receive date RXFPC IN
3 Transmit data TX2PC OUT
4 GND
5 Data terminal ready DTR OUT
8 Clear to send CTS IN
3.1.2. Serial cable configuration
Computer side : DB-25F Cutter side : DB-9M

Pin Nr: 25F Pin Nr: 9M
FRAME Shielding wire FRAME
2 ←→ 2
3 ←→ 3
5+6 ←→ 4
7 ←→ 5
20 ←→ 6+8
Cable length: 3 meter
18 AP-74050, Rev : 1.1

3.2. USB INTERFACE
The used UND interface in the Ultima cutting plotter is the USB version 1.1. Standard in the box is a double-
shielded USB cable with a length of 5m.
3.2.1. USB pin configuration
PIN # SIGNAL
1 VUSB → NC
2 - DATA
3 + DATA
4 GND
19 AP-74050, Rev : 1.1

20 AP-74050, Rev : 1.1

4. TROUBLESHOOTING
When errors occur during cutting or after powering on the machine, some messages may appear on the
display to inform you about the kind of error.
4.1. RECOVERABLE ERRORS
Recoverable errors are mostly related to communication problems or user mistakes.
In this section you will find a summary of problems that might occur during day-to-day use of your cutter and
some hints how to determine the cause of the problem.
1) Power switch is turned ON, but the cutter does not operate.
• Is the power cable connected to the cutter ?
• Is the cutter connected to a power outlet with the specified voltage ?
2) Media is loaded, but the cutter does not operate.

• Is the media hold lever lowered ?
• Is the media properly loaded ?
• Are the paper sensors clean ?
3) Data is being sent from the computer, but the cutter does not react.
• Is there a proper interface cable connected ?
• Is the cutter in ON-LINE mode ?
• Do the interface conditions on the host computer match those set on the cutter ?
4) Data is sent from the computer but errors occur on the cutter’s side.
• Are the output settings correct on the host computer and in the cutting software ?
• Do the interface conditions on the host computer match those set on the cutter ?
• Does the command mode on the host computer match the command mode on the cutter ?
5) Some parts of the design are not well cut.

• Check whether the knife tip is not clogged with material residues.
• Examine the knife blade with a magnifier to see if the tip is not damaged or broken.
• Perform the offset adjustment routine to check cutting quality.
• Perform the internal test cut and check its quality
21 AP-74050, Rev : 1.1

4.2. UNRECOVERABLE ERRORS
The machine will stop working when an unrecoverable error occurs.
To clear the error message, the machine needs to be powered OFF and ON again. (Wait ± 7 seconds
between power OFF/ON).
Refer to the following chart for error code explanation :
NOYENCODER : No Y encoder, check connectors or call service.

YPOSENCTURN : Y+ encoder turn, check connectors or call service.
YNEGENCTURN : Y- encoder turn, check connectors or call service.
YXSWAPPED : YX are swapped, check connectors or call service.
NOXENCODER : No X encoder, check connectors or call service.
XPOSENCTURN : X+ encoder turn, check connectors or call service
XNEGENCTURN : X- encoder turn, check connectors or call service.
XYSWAPPED : XY are swapped, check connectors or call service.
YPOSERROR : X position error, PWM switched off as a safety.
XPOSERROR : Y position error, PWM switched off as a safety.
ZPOSERROR : Z position error, PWM switched off as a safety.
DRAMERROR0 : MEMORY size allocation error
DRAMERROR1 : MEMORY allocation lower limit error
DRAMERROR2 : MEMORY allocation upper limit error
GENYENCODER : General Y encoder failure, PWM switched off as a safety.
GENXENCODER : General X encoder failure, PWM switched off as a safety.
SERIALOFW : Serial Buffer Overflow Error.
VECTOROFW : Vector Buffer Overflow Error.
SERVOOFW : Servo Buffer Overflow Error.
NOZENCODER : No Z encoder, check connectors or call service.
ZPOSENCTURN : Z+ encoder turn, check connectors or call service
ZNEGENCTURN : Z- encoder turn, check connectors or call service.
GENZENCODER : General Z encoder failure, PWM switched off as a safety.
RAMCARDAAAA : RamCard Error while writing 'AAAA' code.
RAMCARD5555 : RamCard Error while writing '5555' code.
UNDEFCARD : Undefined card inserted.
UNDEFCARDWP : Undefined card inserted and write protected.
CORRUPTFCCA : Corrupt 'FCCA' code, Flash incorrectly loaded.
Communication errors are caused by a problem in the communication between the cutter and the host
computer. They can be caused by errors related to the communication conditions, errors due to a defective
handshake or command format errors in the ESCAPE sequences.
KEYB_COMM_CHECKSUM : KEYB communication checksum problem

UART1_COMM_ERROR : UART1 communication error
UART2_COMM_ERROR : UART2 communication error
UART2_SENDTOKEYB_ERROR : UART2 send to keyb problem
Language errors occur when command data entered from the host computer does not match the data
format of the command mode currently activated on the cutter’s side. The error can be caused by a
difference in command type or by a syntax error.
PGTOOSHORT : PG error : Media too short to perform a 'PG;'.

PGM0TOOSHORT : PG Mode 0 Error : Media too short to perform a 'PG;'.
DRAWERROR00 : Out of limit error, vector has been clipped.
22 AP-74050, Rev : 1.1

4.3. PROBLEM SYMPTOMS AND SUGGESTED ACTIONS
4.3.1. Processor errors
PROBLEM SYMPTOM POSSIBLE CAUSE SUGGESTED ACTIONS

• Error code 0 • Poor connection between • Check cable and connection
• Watch dog timeout main and terminal board. • Replace mainboard
• Bus trap error • Mainboard failure
• Address trap error
• Illegal instruction (MC68020)
• Zero divide
• General processor failure
• Interrupt failure
• 1010 CPU failure
• 1111 CPU failure
• DRAM error
• SRAM error
• Extended RAM error • Poor extended RAM • Check connection

connection • Replace extended RAM
• Bad extended RAM
4.3.2. X-Y servo errors

• OUT of SYNC X • Defective motor / encoder • Replace motor / encoder
• OUT of SYNC Y • Loose drive pulley • Fix pulley or replace motor /
• X position Timeout • Failure in drive circuit encoder
• Y position Timeout • Poor connection of motor/ • Replace main PC board
• X over current encoder • Check cables and
• Y over current • Too much friction in X or Y connections
• X overload axis • Check X and Y movement
• Y overload
• X Encoder fail
• Y Encoder fail
• Encoder failure
• Driver failure
4.3.3. Cutting head errors

• Position Timeout Moving Coil • Blade is too far out • Check knife holder
(MC) • Sheet off mechanism blocks • Check blade depth
• OVER CURRENT Moving Coil UP/DOWN movement • Check sheet off mechanism
(MC) • Head flex cable bad or poor • Check connections or replace
• A/D failure Moving Coil (MC) connection head flex cable
• Bad cutting head • Replace cutting head
• Failure in drive circuit • Replace main PC board
23 AP-74050, Rev : 1.1

4.3.4. E-pos errors

Problem with the E-pos system Laser not working Check connection
Sensor not working Replace head
Laser damaged
Sensor damaged
4.3.5. Other errors

• System is dead : • Power failure • Check power cord
• No movement • Defective power supply (P/S) • Check wall outlet
• No LED’s lighted • Defective mainboard • Check fuse on P/S
• Check LEDs on P/S
• Replace P/S
• Replace mainboard
• Display lighted but no • Defective mainboard • Replace mainboard

movement of the motors and • Poor connection between • Check cable connections
cutting head. main and terminal board
• Plotter does not pre-feed • Pressure roller lever is not • Lower the lever
media. DOWN • Check the lever sensor
• Bad lever sensor • Load media properly
• Both media sensors are not • Clean or replace media
covered sensors
• Media sensors dusty or bad
• Illegal mainboard revision • Mainboard version is not • Use correct mainboard

compatible
• Wrong mainboard • Mainboard is not compatible • Use correct mainboard
• Plotter has pre-feeded media • Plotter is OFF-line • Put plotter in ON-line

but does not respond to data • Interface cable not connected • Check interface cable
or bad • Check plotter driver
• Wrong plotter driver • Check interface parameters
• Wrong interface parameters • Check port or replace main
• Bad interface port PC board
• Plotter is responding to data, • Wrong interface parameters • Check interface parameters

but error messages appear on • Wrong cable configuration • Check interface cable
the display.
• Plotter is cutting but quality is • Blade worn or broken • Replace blade

not acceptable • Blade is not turning smooth • Check or replace knife holder
• Offset is not correct • Perform offset procedure
• Blade is too far out • Adjust knife depth
• Cutting force is too high • Reduce cutting force
• Cutting mat worn • Replace cutting mat
• Wrong plotter driver • Select correct plotter driver
• Play on cutting head • Check or replace cutting head
• Drive belt tension not correct • Check or adjust belt tensions
• X or Y motor defective • Replace X or Y motor
24 AP-74050, Rev : 1.1


• Media tracking problems • Media is not loaded straight in • Load media as described in
• Media skews during cutting or the machine the User’s Guide
loading. • Grid rollers dirty • Clean grid rollers
• Grid rollers or pressure rollers • Replace grid rollers or
worn pressure rollers
• Speed or acceleration too • Decrease
high • Cutting speed
• Pressure roller pressure not • Pen/UP speed
correct • Cutting acceleration
• Media backing is very slippery • Pen/UP acceleration
(Teflon based) • Adjust pressure roller
pressure
• Change media type or
decrease speed acceleration
25 AP-74050, Rev : 1.1

26 AP-74050, Rev : 1.1

5. DIAGNOSTIC MODE
5.1. HOW TO GET IN DIAGNOSTIC MODE?
To go in Diagnostic Mode, please follow the instructions mentioned below.
Step 1: Power ON the Ultima cutting plotter.
Notes :
Let the unit perform the initialise routine (determination of left and right borders). In case
media is loaded media will also be measured.
Step 2: Press the [PRESETS], [ORIGIN], [CONTOUR CUTTING] and [TEST] key simultaneously.
Step 3: The Ultima cutting plotter will enter the Diagnostic Mode. The display on the Operation Panel
shows following message:
Diagnostics Mode
is entered
Press any key
Step 4: Press any key.
5.2. HOW TO LEAVE IN DIAGNOSTIC MODE?
To leave the Diagnostic Mode, please follow the instructions mentioned below.
Step 1: Press the [PRESETS], [ORIGIN], [CONTOUR CUTTING] and [TEST] key simultaneously.
Step 2: The Ultima cutting plotter will leave the Diagnostic Mode. The display on the Operation Panel
shows following message:
Diagnostics Mode
is leaved
Press any key
Step 3: Press any key.
27 AP-74050, Rev : 1.1

5.3 DIAGNOSTIC MENU – MENU OVERVIEW
5.3.1 Factory default
To set the values of the machine back to factory default, please follow the instructions below.
Step 1: Go into Diagnostic Mode.
Step 2: Press the [TEST] key.
Step 3: By pressing the [UP] or [DOWN] key select “Factory default”. The display on the Operation
Panel will show the following message.
Diagnostics :
Factory default
Choose item
Step 4: Press the [ENTER] key. Values are set to factory default, a double beep will sound. The display
will show the following message :
DIAGNOSTIC MODE
PRESS TEST
BUTTON TO SELECT
AN ITEM
28 AP-74050, Rev : 1.1

5.3.2 EPOS readout
To check the photodiode of the Ultima cutting plotter, please follow the instructions below.
Step 2: Press the [ENTER] key.
Step 3: By pressing the [UP] or [DOWN] key select “EPOS readout”. The display on the Operation Panel
will show the following message.
Diagnostics :
Epos Readout
Choose item
Step 4: Press the [ENTER] key. The display will show the following message:
Photodiode
ACD value :
***
Change the value
Step 5: By covering or uncovering the front sensor, the display will show the relative status of the
sensor.
Step 6: Press the [ENTER] key to exit the “EPOS readout menu”
29 AP-74050, Rev : 1.1

5.3.3 Setting plot
To make a setting plot, please follow the instructions below.
Step 1: Perform a “Factory default” in Diagnostic mode.
Step 2: Install a pen.
Step 3: Press the [TOOL] key and select “pen tool”.
Step 4: Install media.
Step 7: By pressing the [UP] or [DOWN] key select “Settings plot”.
Step 8: Press the [ENTER] key. The Laser will light up. The display will show the following message :
Step 9: The Ultima cutting plotter will draw the settings plot.
30 AP-74050, Rev : 1.1

5.3.4 Serial Number
Only to be used during production of the unit.
31 AP-74050, Rev : 1.1

5.3.5 Robot 2 test
To perform a Robot 2 Test, please follow the instructions below.
Step 2: Load media.
Step 3: Install a knife.
Step 5: By pressing the [UP] or [DOWN] key select “Robot 2 Test”. The display on the Operation Panel
Diagnostics :
Robot 2 Test
Choose item
Step 6: Press the [ENTER] key. The Ultima cutting plotter will cut a picture. Check the patterns.
Especially look for good quality of the corners and easy weeding. If this is not the case, readjust
the Ultima cutting plotter.
32 AP-74050, Rev : 1.1

5.3.6 Set Accuracy
To check the accuracy of the Ultima cutting plotter, please follow the instructions below.
Step 3: By pressing the [UP] or [DOWN] key select “Set accuracy”. The display on the Operation Panel
Diagnostics :
Set accuracy
Choose item
Step 4: Press the [ENTER] key. The display will show the following message :
Set real X value

Ref : 20000
Val : 20000
UP/DOWN & ENTER
Step 5: By pressing the [ARROW] keys change the X value by steps of 10 digits.
By pressing the [UP] or [DOWN] key change the X value accurately.
Set real Y value

Ref : 20000
Val : 20000
UP/DOWN & ENTER
Step 7: By pressing the [ARROW] keys change the Y value by steps of 10 digits.
By pressing the [UP] or [DOWN] key change the Y value accurately.
Step 8: Press the [ENTER] key to exit the “Set accuracy” menu.
33 AP-74050, Rev : 1.1

5.3.7 Robot 1 test
To perform a Robot 1 Test, please follow the instructions below.
Step 2: Load media.
Step 5: By pressing the [UP] or [DOWN] key select “Robot 1 Test”. The display on the Operation Panel
Diagnostics :
Robot 1 Test
Choose item
34 AP-74050, Rev : 1.1

5.3.8 Calibrate E-pos
During calibration the distance between the laser and the pen/knife is measured (and stored).
Measurement can be done in two ways, namely:
¾ Automatic calibration
¾ Manual calibration (with knife)
¾ Manual calibration (with pen)
It is possible to check visually the calibration by using the ‘Calibration with pre-drawn sample square’.
1. Automatic calibration
To calibrate the E-pos system using the ‘Automatic calibration’, please follow the instructions mentioned
below.
Step 1 : Install a knife.
Step 2 : Press the [TOOL] key and select ‘knife’.
Step 3 : Install a black vinyl.
Step 4 : Press the [TEST] key.
Step 5 : By pressing the [UP] or [DOWN] key select ‘EPOS align tune --> automatic. The Display on the
Operation Panel will show the following message.
Testplot
EPOS align tune
→ automatic
Choose testfile
Step 6 : Press the [ENTER] key. The Ultima cutting plotter will cut a square. After cutting following
message will appear.
Measure box is
cut please
Weed out and
Press a button
Step 7 : Peel of the box cut by the Ultima cutting plotter.
Step 8 : Press the [ENTER] key.
Step 9 : The laser of the Ultima cutting plotter will measure the box. The distance between laser and
knife is calculated and stored.
Step 10 : Calibration of the E-pos system with the ‘automatic calibration’ method is done. Following
EPOS
Calibration
done
35 AP-74050, Rev : 1.1

2. Manual calibration with knife

To calibrate the E-pos system using the ‘manual calibration’, please follow the instructions mentioned below.
Step 1 : Install a knife.
Step 2 : Press the [TOOL] key and select ‘knife’.
Step 3 : Install a black vinyl.
Step 4 : First set the ORIGIN in the middle of the media.

¾ Press the [Origin] key.
¾ Select ‘Manual’.
¾ Use the [ARROW] keys to position the tool head in the middle of the media.
¾ Press the [ENTER] key to confirm.
Step 6 : By pressing the [UP] or [DOWN] key select ‘EPOS align tune --> manual’. The Display on the
Testplot
EPOS align tune
→ manual
Choose testfile
Step 7 : Press the [ENTER] key. The Ultima cutting plotter will start cutting two square boxes. After
drawing following message will appear.
Measure box is
cut please
Weed out and
Press a button
Step 8 : Peel of the boxes cut by the Ultima cutting plotter.
Step 9 : Press the [ENTER] key.
Step 10 : The Ultima cutting plotter will move the laser to the point where both squares touch. Following
* Epos Calibrate. *
Please move
laser pointer to
Cross and enter
Step 11 : If necessary, use the [ARROW] keys to position the laser exactly onto the point where both
squares touch. Do not keep the [ARROW] keys pressed, pressing the keys only causes one
movement.
Step 12 : Press the [ENTER] key to confirm the position of the laser. The distance between laser and knife
is calculated and stored.
Step 13 : Calibration of the E-pos system with the ‘manual calibration’ method is done.
36 AP-74050, Rev : 1.1

3. Manual calibration with pen

To calibrate the E-pos system using the ‘manual calibration’, please follow the instructions mentioned below.
Step 1 : Install a pen.
Step 2 : Press the [TOOL] key and select ‘pen’.
Step 3 : Install an A4-format paper.
Step 4 : First set the ORIGIN in the middle of the media.

¾ Press the [Origin] key.
¾ Select ‘Manual’.
¾ Use the [ARROW] keys to position the tool head in the middle of the media.
¾ Press the [ENTER] key to confirm.
Step 6 : By pressing the [UP] or [DOWN] key select ‘EPOS align tune --> manual’. The Display on the
Testplot
EPOS align tune
→ manual
Choose testfile
Step 7 : Press the [ENTER] key. The Ultima cutting plotter will start drawing a cross.
Step 8 : The Ultima cutting plotter will move the laser to the point where both lines intersect. Following
* Epos Calibrate. *
Please move
laser pointer to
Cross and enter
Step 9 : If necessary, use the [ARROW] keys to position the laser exactly onto the point where both lines
intersect. Do not keep the [ARROW] keys pressed, pressing the keys only causes one
movement.
Step 10 : Press the [ENTER] key to confirm the position of the laser. The distance between laser and knife
is calculated and stored.
Step 11 : Calibration of the E-pos system with the ‘manual calibration’ method is done.
37 AP-74050, Rev : 1.1

4. Visual check of the calibration

It is possible to check the calibration of the Ultima cutting plotter by using the calibration with pre-drawn
sample square’ method. To check the calibration, please follow the instructions mentioned below.
Before performing a ‘calibration with pre-drawn sample square’ make sure to have the files ‘kot.eps’.
Step 1 : Prepare your printer to ‘Ready-to-print’.
Step 2 : Import the kot.eps file and RIP this file.
Step 3 : Print out the ripped kot.eps file.
Step 4 : Power ON the Ultima cutting plotter and install a pen.
Step 5 : Load the printed output into the Ultima cutting plotter.
Step 6 : By pressing the [UP] or [DOWN] key select ‘EPOS alignment --> test plot’. The Display on the
Testplot
EPOS alignment
→ test plot
Choose testfile
Step 7 : Press the [ENTER] key. The laser of the Ultima cutting plotter will measure the box and will start
(re)drawing the diagonals and the small rectangle.
Step 8 : Check if the drawn lines are well positioned according to the printed lines.
38 AP-74050, Rev : 1.1

5.3.9 Measure Y
To measure the height difference in the Y direction of the Ultima cutting plotter, please follow the instructions
below.
Step 3: By pressing the [UP] or [DOWN] key select “Measure Y”. The display on the Operation Panel
Diagnostics :
Measure Y
Choose item
Measure drum
Please wait
While Ultima
Is measuring
Measure drum
Max : 0
Delta : 18
U/D & ENTER
Step 5: Press the [UP] or [DOWN] key to change the value.
Step 6: Press the [ENTER] key to exit the “Measure Y” menu.
39 AP-74050, Rev : 1.1

5.3.10 Penforce check
To check the penforce of the Ultima cutting plotter, please follow the instructions below.
Step 1: Install media.
Step 2: Install the measure-equipment.
Step 5: By pressing the [UP] or [DOWN] key select “Penforce check”. The display on the Operation
Diagnostics :
Penforce check
Choose item
Penforce check
Current force :
100.000000
UP/DOWN & ENTER
Step 7: Check the measured value with the displayed value.
Step 8: By pressing the [UP] or [DOWN] key change the value of the display to the corresponding
measured value.
Step 9: Press the [ENTER] key to exit the “Keyboard LED’s” menu.
40 AP-74050, Rev : 1.1

5.3.11 Panel test 2
To check the buttons of the Ultima cutting plotter, please follow the instructions below.
Step 3: By pressing the [UP] or [DOWN] key select “Panel test 2”. The display on the Operation Panel
Diagnostics :
Panel test 2
Choose item
Keyboard LED’s
→ SHEET LED
MU/MD = change
ENTER = exit
Step 5: By pressing the [UP] or [DOWN] key select a LED. In normal condition the LED displayed will
light up on the operation panel.
Step 6: Press the [ENTER] key to exit the “Keyboard LED’s” menu.
41 AP-74050, Rev : 1.1

5.3.12 Panel test 1
To check the buttons of the Ultima cutting plotter, please follow the instructions below.
Step 3: By pressing the [UP] or [DOWN] key select “Panel test 1”. The display on the Operation Panel
Diagnostics :
Panel test 1
Choose item
Keyboard check
→ No button
Press 3 times
ENTER to cancel
Step 5: Press a key. The display will show the selected button.
Step 6: Press three times the [ENTER] key to exit the “Panel test 1” menu.
42 AP-74050, Rev : 1.1

5.3.13 Actuator write
To check the buzzer, LED’s, sheet-off knife or laser of the Ultima cutting plotter, please follow the instructions
below.
Step 3: By pressing the [UP] or [DOWN] key select “Actuator write”. The display on the Operation Panel
Diagnostics :
Actuator write
Choose item
Actuator write
Mainboard LED’s :
OFF
U/D & ARROW U/D
Step 5: Press the [ARROW] key change the status of the item.
Step 6: Press the [UP] or [DOWN] key select buzzer, LED’s, sheet-off knife or laser.
Step 7: Press the [ENTER] key to exit the “Actuator write” menu.
43 AP-74050, Rev : 1.1

5.3.14 Sensor readout
To check the sensors of the Ultima cutting plotter, please follow the instructions below.
Step 3: By pressing the [UP] or [DOWN] key select “Sensor readout”. The display on the Operation
Diagnostics :
Sensor readout
Choose item
Sensor Read
X front sensor :
OFF
Change the value
Step 5: By covering or uncovering the front sensor, the display will show the relative status of the
sensor.
Step 6: By pressing the [UP] or [DOWN] key select the newt sensor test. Sensors to be checked are :
• “X rear sensor” = to check the X rear sensor → cover or uncover the rear sensor
• “Lever sensor” = to check the lever sensor → detect up or down position of the Lever
• “Y flap sensor” = to check the position-sensor of the pressure rollers → moves head above
the pressure rollers.
Step 7: Press the [ENTER] key to exit the “Sensor readout” menu.
44 AP-74050, Rev : 1.1

5.3.15 Quality Test
To perform a Quality Test, please follow the instructions below.
Step 2: Load media.
Step 5: By pressing the [UP] or [DOWN] key select “Quality Test”. The display on the Operation Panel
Diagnostics :
Quality Test
Choose item
45 AP-74050, Rev : 1.1

5.3.16 Update firmware keyboard
Notes :
Please perform this function after a firmware upgrading. Without this procedure, the
panel keyboard remains in the old firmware version.
To perform an update firmware keyboard, please follow the instructions mentioned below.
Step 3: By pressing the [UP] or [DOWN] key select “Update Firmware keyboard”. The display on the
Diagnostics
Update Firmware
keyboard
Choose item
Step 4: Press the [ENTER] key. The display on the Operation Panel will show the following message.
Code Update
Please wait …
Step 5: After approximately 45 second a beep will sound and following message appears (short) on the
display.
Mutoh Europe NV
Version ***
Initializing
Please wait
Step 6: The keyboard has been updated and reset.
Step 7: You will automatically enter the Normal Mode.
46 AP-74050, Rev : 1.1

5.3.17 Aging
To check the movement of the Head and Grid Rollers please follow the instructions below.
Step 3: By pressing the [UP] or [DOWN] key select “Aging”. The display on the Operation Panel will
show the following message.
Diagnostics :
Aging
Choose item
Step 4: Press the [ENTER] key. The Head will start to move. The display will show the following
message :
Smooting
Page Length
VS/ZF Settings
Emulation
Step 5: To stop the movements pres the [TEST] key. The display on the Operation Panel will show the
following message.
Diagnostics :
Aging
Choose item
Step 6: Press the [ENTER] key. The machine will stop all movements. The display will show the
following message :
Smooting
Page Length
VS/ZF Settings
Emulation
Step 7: Load media and repeat step 1 to 7 to check the movement of the grid rollers
47 AP-74050, Rev : 1.1

5.4 DIAGNOSTIC MODE – ERROR
In case you cannot power ON the Ultima cutting plotter normally, you are unable to enter Diagnostic Mode.
If this is the case, please follow the instructions mentioned below to enter Diagnostic Mode.
Notes :
Only a small amount of tests can be performed in this diagnostic mode.
5.4.1 How to get in diagnostic mode.
Step 1: Power ON the Ultima cutter plotter.
Notes :
Don’t let the machine complete his start up.
Step 2: Press the [TEST] and [PRESETS] key simultaneously when following screen is displayed.
VERSION ID
*********************
SR V *.**
Date Hour
Step 3: The Ultima cutting plotter will enter the Diagnostic Mode. The display on the Operation Panel
shows following message.
DIAGNOSTIC MODE
PRESS TEST
BUTTON TO SELECT
AN ITEM
Step 4: Press the [TEST[ key to start the several tests.
5.4.2 How to leave diagnostic mode
Step 1: The machine needs to be powered “OFF” and “ON” again. (Wait ± 7 seconds between power
OFF/ON)
48 AP-74050, Rev : 1.1

5.5 ULTIMA SHORTCUT KEY COMBINATIONS.
PRESETS+ORIGIN+TEST+CONTOUR CUTTING: Enter/Leave diagnostic mode.

PRESETS + ORIGIN + SPEED + FORCE: Update the keyboard firmware.
TEST + COUNTOUR CUTTING + OFFSET + TOOL: Reset the keyboard.
ORIGIN + RIGHT: Activate sheet off knife.
ORIGIN + LEFT: Deactivate sheet off knife.
TEST + LEFT: Set laser LED on.
TEST + RIGHT: Set laser LED off.
CONTOUR + (UP or DOWN or LEFT or RIGHT): EPOS line search for maximum 4 cm.
CONTOUR + TEST + RIGHT: Scan a postnet code from left to right.
CONTOUR + TEST + UP: Scan a postnet code from down to up.
PRESETS + TEST: Startup in diagnostic (combination works only at
startup when firmware version is showed).
49 AP-74050, Rev : 1.1

50 AP-74050, Rev : 1.1

6. PARTS REPLACEMENT AND

ADJUSTMENT
6.1. MAINTENANCE ACCESS TABLE FOR PARTS

REPLACEMENT
Removal of the following cover gives access to the following part or mechanical adjustment :
COVER Gives access to

Left cover Y-axis return pulley assy
Y-axis drive belt tension adjustment
Right cover Y-motor

Y-drive pulley assy
Y-drive belt (short) tension adjustment
Pressure roller UP/DOWN sensor
Pressure roller UP/DOWN mechanism
Keyboard assy
Y-rail cover Pressure roller assy

Y-rail assy
Penhead flex cable assy
Pressure roller pressure adjustment
PCB-box Main/driver board assy

Power supply board assy
X-motor assy
X-drive belt tension adjustment
Fan motor
Grid cover Grid rollers

Paper sensors
Head cover E-pos system

Coil
Cutter holder
51 AP-74050, Rev : 1.1

6.2. MECHANICAL PARTS
6.2.1. Covers Left : removal and installation
Step 1: Remove the two screws at the bottom of the cover.
Step 2: Remove the two screws at the inside of the cover.
Step 3: Remove the cover by pulling the cover carefully up at the bottom.
Notes :
To reinstall Left Cover perform above steps in reversed order.
52 AP-74050, Rev : 1.1

6.2.2. Cover Right : removal and installation
Step 1: Remove the two screws at the bottom of the cover.
Step 2: Remove the two screws at the inside of the cover.
Step 3: Remove the cover by pulling the cover carefully up at the bottom.
Notes :
To reinstall the Right Cover perform above steps in reversed order.
53 AP-74050, Rev : 1.1

6.2.3. PCB box: open and close
Step 1: Remove the Conveyor System

a. Remove the Conveyor Rollers.
b. Loosen the three screws at the Left Conveyor Support System.
c. Loosen the three screws at the Right Conveyor Support System.
d. Remove the Conveyor System.
Step 2: Remove the three screws at the rear of the PCB Box.
Step 3: Remove the three screws at the front of the PCB Box.
Step 4: The PCB box will turn open.
Notes :
Close the PCB box by performing the above steps in reversed order.
54 AP-74050, Rev : 1.1

6.2.4. Keyboard: removal and installation
Step 1: Disconnect the Keyboard Cable.
Step 2: Remove the Keyboard.
Notes :
To reinstall the Panel perform above steps in reversed order.
6.2.5. Y-rail Cover : removal and installation
Step 1: Remove the Keyboard. (Please refer to 6.2.4. Keyboard)
Step 2: Remove the two screws at the rear of the Y-rail Cover.
Step 3: Remove the two screws at the front of the Y-rail Cover.
Step 4: Remove the Y-rail Cover.
Notes :
To reinstall the Y-rail Cover perform above steps in reversed order.
6.2.6. Front Paper Sensor : removal and installation
Step 1: Remove the Left Cover. (Please refer to 6.2.1. Cover Left)
Step 2: Remove the Right Cover. (Please refer to 6.2.2. Cover Right)
Step 3: Remove the two screws at the left side of the Front Cover.
Step 4: Remove the two screws at the right side of the Front Cover.
Step 5: Open the PCB box (Please refer to 6.2.3. PCB box).
Step 6: Pull out the Front Plate.
Step 7: Loosen the screw, disconnect connector (F) and remove the Front Paper Sensor.
Notes :
To reinstall the Front Paper Sensor perform above steps in reversed order.
55 AP-74050, Rev : 1.1

6.2.7. Rear Paper Sensor : removal and installation
Step 1: Remove the Left Cover. (Please refer to 6.2.1. Cover Left)
Step 2: Remove the Right Cover. (Please refer to 6.2.2. Cover Right)
Step 3: Remove the two screws at the left side of the Rear Cover.
Step 4: Remove the two screws at the right side of the Rear Cover.
Step 6: Pull out the Rear Plate.
Step 7: Loosen the screw, disconnect connector (R) and remove the Rear Paper Sensor.
Notes :
To reinstall the Rear Paper Sensor perform above steps in reversed order.
6.2.8. Cutting Head : removal and installation
Step 1: Remove the Y-rail Cover. (Please refer to 6.2.5. Y-rail Cover)
Step 2: Remove the head cover by removing the two screws in the front of the cover.
Step 3: The head cover can be removed by sliding upwards.
Step 4: Open the 2 white connectors by sliding them to the front and pull away the 2 flex cables from the
connectors.
Step 5: Remove the head PCB on top of the head by 2 screws ‘C’ (Please refer to picture mentioned
below) and lay it somewhere on the Y-rail where the flex cable cannot be damaged.
56 AP-74050, Rev : 1.1

Step 6: Remove screw ‘A’ that fix the cutting head to the drive belt.
It is strongly recommended to use a magnetised –screwdriver in order not to drop the screw
inside the head.
Step 7: Remove screw ‘B’ on the top of the head and slide away the blade spring.
Notes :
To reinstall the cutting head perform above steps in reversed order.
Caution :
After replacement of the cutting head the following electronically adjustments have to be
performed :
Cutting mat height measurement

Adjusting the sheeting off system
Pen force calibration
57 AP-74050, Rev : 1.1

6.2.9. Grid Rollers : removal and installation
Step 1: Remove the Left Cover. (Please refer to 6.2.1. Left Cover)
Step 2: Remove the Right Cover. (Please refer to 6.2.2. Right Cover)
Step 3: Remove the Y-rail Cover. (Please refer to 6.2.5. Y-rail Cover)
Step 4: Unscrew the two screws from the X-motor a few turns and remove the X-drive belt.
Step 5: Unscrew all the grid rollers (with 1.5mm hex-key) and pull out gently the shaft out of the
machine. In this way every grid roller can be removed from the shaft.
Caution :
Never replace only one grid roller but always the whole set. Replacement of only one
grid roller may result in noticeable deviation of media tracking!
Before unscrewing the grid rollers, mark the position of every roller on the shaft. This
will simplify the reinstallation.
NEVER unscrew or change the position of the bearing blocks on the X-rail as this will
result in misalignment of the grid roller shaft!
Notes :
To reinstall the grid rollers perform above steps in reversed order.
Caution :
After reinstallation of the grid rollers, the X-drive belt tension should be adjusted (Please
refer to the adjustment of the X-drive belt).
58 AP-74050, Rev : 1.1

6.2.10. Y-drive belt (long) : removal and installation
Step 1: Remove the Left Cover (Please refer to 6.2.1. Left Cover).
Step 2: Remove the Right Cover (Please refer to 6.2.2. Right Cover).
Step 3: Remove the Y-rail Cover (Please refer to 6.2.5. Y-rail Cover).
Step 4: Remove the cutting head.
Step 5: On the left hand side of the machine, unscrew both screws #5 (2) ± 5 turns in order to get the
tension of the belt (Please refer to picture mentioned below).
Step 6: Remove two screws #4 and one plate #3 from the belt connection assy and pull the belt
complete out of the Y-rail. (Please refer to the picture on the next page.)
(1) Y-drive belt (long) : Installation and adjustment.
Step 1: Hold the belt in front of the machine and push one end trough the slit of the right side plate.
Turn the belt around the pulley and push it in the second slit to enter the slide at the back of the
Y-rail.
Push it as far as it goes and then use a flash light and look into the slit at the left side of the
machine.
With a pair of tweezers try to grab the belt and pull it through the slit.
Turn the belt around the return pulley and push it through the front slit to arrive at the starting
point of the belt again.
59 AP-74050, Rev : 1.1

Step 2: Close the belt with the connection plate assy and be sure that all the teeth of the connection
plate are used to hold the belt.
Step 3: Turn the 2 screws on the return pulley an equal amount of turns in CW (Clockwise direction) in
order to get a little tension on the belt.
Step 4: Install the cutting head (Please refer to 6.2.8. Cutting head).
Step 5: Move the head manually from the left to the right and look for the tracking of the belt on the
return pulley.
If the belt moves upwards, turn the top screw CW or the bottom screw CCW (counter-clockwise).
If the belt moves downwards, turn the top screw CCW or the bottom screw CW.
The target is that the tension of the belt stays stable at the surface of the return pulley on the
complete range of the cutting head.
Step 6: Similar to step 5 check the track of the belt on the drive pulley.
If the belt moves upwards turn the screw 9 (Please refer to the picture mentioned below) CW.
If the belt moves downward turn screw 9 CCW.
60 AP-74050, Rev : 1.1

Caution :
Pay attention to the tension on the belt during this alignment.

The tension should stay between acceptable values (Please refer to step 7).
Step 7: Move the head to the right end of the Y-rail and measure with a bar tension gauge (range : 500g,
MUTOH Part# JD-41446B) the tension of the belt in the middle of the Y-rail (Please refer to
picture mentioned below).
Push the belt with the bar tension gauge (with steel belt tension attachment MUTOH part# JD-
41565) to touch the rail and release gently the pressure on the gauge.
The movement that the belt starts to release from the rail is the moment of reading the value on
the bar tension gauge.
The values are different for each size machine :
SC-850D SC-1400D
180 ± 5 g 125 ± 5 g
The tension can be adjusted by turning the screws on the return pulley CW for more tension and CCW for
less tension.
Caution :
While adjusting the tension, keep on checking the track of the belt on the return pulley
(Please refer to step 5).
61 AP-74050, Rev : 1.1

6.2.9. Pressure roller pressure adjustment
Step 1: Switch off the machine and place the pressure rollers on top of a grid roller.
Step 2: Remove the Y-rail Cover (Please refer to 6.2.5. Y-rail Cover).
Step 3: Take a piece of polyester film of ± 300 cm long, 2.5 mm wide (12” X 1”) and put it between the
grid roller and the pressure roller (Please refer to the picture mentioned below).
Attach the bar tension gauge (range 5 kg, MUTOH Part# JD-41446C) to the pressure roller shaft
with a piece of rope or with the pressure measurement attachment JD-41563 and pull
simultaneously the film and the tension gauge under 90° angle.
The moment that the film is slipping between the rollers is the moment to read the value on the
tension gage.
The value should be 3.5 kg ± 0.1 kg.
To adjust the pressure, change the spring tension by turning the nuts A (Please refer to the
figure mentioned below) CW to increase or CCW to decrease the pressure on the rollers.
62 AP-74050, Rev : 1.1

6.3. ELECTRONICAL PARTS
6.3.1. Main PC board : removal and installation
N° Description N° Description N° Description

1 Serial port 7 Flex cable 2 head 13 Fan 1
2 Keyboard cable connector 8 Front paper sensor 14 Fan 2
3 USB port 9 Rear paper sensor 15 Motor X
4 Flash card connector 10 Cover sensor (not used) 16 Motor Y
5 Encoder X 11 Lever sensor 17 Power connector
6 Encoder Y 12 DIP switch
Step 1 : Open the PCB box (Please refer to 6.2.3. PCB box).
Step 2 : Remove the protection cap.
Step 3 : Unplug all the connectors, remove all screws from the board and remove the board. Do not
forget to remove the screws from the parallel and serial communication connector.
Notes :
Pay attention to the position of all connectors and the proper place of all the cables.
This will simplify the installation.
To reinstall the Main PC board perform above steps in reversed order.
63 AP-74050, Rev : 1.1

Notes :
Please note that the connector of the Cover Sensor (J6) is not used.
<
64 AP-74050, Rev : 1.1

6.3.2. Head board installation
To install the Head Board, please follow the instructions mentioned below.
Important :
Before working on a machine, always power OFF the unit and pull out the power
supply cable. Otherwise you may suffer an electric shock.
Step 1: Disconnect the Keyboard Cable.
Step 2: Remove the Operation Panel.
Step 3: Remove the two screws at the rear of the Y-rail Cover.
Step 4: Remove the two screws at the front of the Y-rail Cover.
Step 5: Remove the Y-rail Cover.
Step 6: Remove the head cover by removing the screw in the middle of the cover and unscrew the
bottom screw a few turns. The head cover can be removed by sliding upwards.
Step 7: Remove the connectors. Remove the 2 screws on top of the Head board and remove the Head
Board
Step 8: Install the new Head Board. Reconnect the connectors.
Connections on the New Head Board
65 AP-74050, Rev : 1.1

Notes :
Please note that the flex head cable connection is made onto the second connector on
the new Head Board.
6.3.3. Power supply board : removal and installation
Step 1: Open the PCB box (Please refer to 6.2.3.PCB box).
Step 2: Remove the protection cap.
Step 3: Remove the connectors and the screw from the grounding wire and remove the board.
Notes :
To reinstall the board perform above steps in reversed order.
6.3.4. Power supply output connections
PIN SIGNAL COLOUR PIN SIGNAL COLOUR

1 + 5V Red 7 FG Green
2 + 5V Red 8 - 12V Blue
3 SG Black 9 AG Black
4 SG Black 10 + 12Vb Orange
5 + 12Va Orange 11 PG1 Black
6 + 40V Yellow 12 PG2 Black
66 AP-74050, Rev : 1.1

6.3.5. X-motor and drive belt : removal and installation
Step 1: Remove the right cover (Please refer to 6.2.2. Right Cover).
Step 2: Open the PCB box (Please refer to 6.2.3.PCB box).
Step 3: Remove the X-motor connector and the X-encoder connector from the Main PCB.
Step 4: Remove the screws from the X-motor and remove the belt and the motor.
Notes :
To reinstall the x-motor perform above steps in reversed order.
(1) X-drive belt : Tension adjustment.
Step 1: From the side of the PCB box, attach a piece of rope (or the pressure measurement attachment
JD-41563) around the motor body as close as possible to the side plate.
Step 2: Be sure that the motor screws are not fixed and pull the bar tension gauge (range 5kg, MUTOH
part# JD-41446C) downwards for 3.75 kg ± 0.05 kg.
Turn manually the grid shaft a few turns and fix the motor screws.
67 AP-74050, Rev : 1.1

6.3.6. Y-motor and drive belt : removal and installation
Step 1: Remove the right cover (Please refer to 6.2.2. Right Cover) and open the PCB box (Please refer
to 6.2.3.PCB box). If the drive belt needs to be removed, remove the left cover too (Please refer
to 6.2.1. Left Cover).
Step 2: Remove the Y-motor connector and the Y-encoder connector from the mainboard and pull the
cables out of the PCB box.
Step 3: Remove the 2 screws from the Y-motor and remove the motor.
Notes :
To reinstall the Y-motor perform above steps in reversed order and perform the belt
tension adjustment. (Please refer to point 1) Y-motor and drive belt mentioned below).
Step 4: (Drive belt removal only)
Release the tension on the Y-drive belt (long) (Please refer to 6.2.8 Y-drive belt (long) step 3).
Remove the screw on top of the pulley shaft (Please refer to screw 9 on figure 6.2.8. Y-drive belt
(long) 1) Y-drive belt (long) step 3) and remove the pulley assy from the bracket. If not possible,
the Y-drive belt (long) needs to get more play by turning the screws of the return pulley CCW.
Now the Y-belt (short) can be removed.
(1) Y-motor and drive belt : installation and adjustment.
Step 1: Install the Y-drive belt (short) by performing the above steps in reverse order.
Step 2: Turn in the screws from the Y-motor a few turns, but do not fix them.
Step 3: Attach the bar tension gauge (range 5 kg, MUTOH part# JD-41446C) to the motor shaft (use a
piece of rope or pressure measurement attachment JD-41563) and pull for 3.5 kg ± 0.05 kg.
While pulling the gauge, move the cutting head manually left and right a few times before fixing
the motor screws.
68 AP-74050, Rev : 1.1

6.3.7. Head flex cable : removal and installation
Step 1: Remove the Y-rail cover (Please refer to 6.2.5 Y-rail cover).
Step 2: Remove the head cover by removing the screw in the middle of the cover and unscrew the
bottom screw a few turns. The head cover can be removed by sliding upwards.
Step 3: Open the 2 white connectors by sliding them to the front and pull away the 2 flex cables from the
connectors. Remove the head PCB on top of the head by 2 screws and lay it somewhere on the
Y-rail where the flex cable cannot be harmed.
Step 5: Remove the flex cable from the terminal board.
Step 6: Remove the right cover (Please refer to 6.2.2. Right Cover) and open the cable guides that
holding the flex cable.
Step 7: Remove the flex cable.
Notes :
Pay attention to the position of the cable in the way that it is guided all through the
machine.
This will simplify the installation.
Notes :
To reinstall the head flex cable perform above steps in reversed order.
69 AP-74050, Rev : 1.1

6.3.8. Pressure roller UP/DOWN sensor : removal and installation
Step 1: Remove the right cover (Please refer to 6.2.2. Right Cover).
Step 3: Remove the sensor.
Notes :
To reinstall the pressure roller UP/DOWN sensor perform above steps in reversed order.
70 AP-74050, Rev : 1.1

6.3.9. Fan motors : removal and installation
Step 2: Remove the fan motor cable(s) (red, black, brown) from the main PC board.
Step 3: Remove the fan motor(s) from the suction tube with 2 screws.
Notes :
To reinstall the fan motors perform above steps in reversed order.
71 AP-74050, Rev : 1.1

6.4. HOW TO CORRECTLY INSTALL NEW FIRMWARE
There are three possibilities to update your Ultima Multi-Purpose Cutting Plotter:
• Installation of new firmware with the USB cable

• Installation of new firmware with the serial cable
• Installation of new firmware with a flash card
Notes :
Please perform a “Code Update” after a firmware upgrading. Without performing a

“Code Update”, the panel keyboard remains in the old firmware version.
Please follow the instructions mentioned below to correctly install new firmware into the Ultima cutting plotter.
6.4.1. Installation of new firmware with the USB cable
Notes :
Please make sure that the USB driver is installed!
To install new firmware using a USB cable, please follow the instructions below.
Step 1: In case the power is ON, first turn the power of the machine OFF.
Step 2: Connect the Ultima cutting plotter with your PC by means of a USB cable. Remove the RS232
connection.
Step 4: Go to the “Control Panel – System”.
Step 5: Go to the hardware tab.
Step 6: Press the [Device Manager] button.
72 AP-74050, Rev : 1.1

Step 7: In the “Device Manager” open the list “Ports” (COM & LPT).
Step 8: Check the comport number for the USB serial Port (Mutoh Ultima). In the figure above it is
COM3.
Step 9: Start the Ultima update utility on your PC.
Step 10: Select the correct comport (in this case COM3).
Step 11: Press the [Connect] button.
Step 12: The status bar starts moving.
Step 13: Press the [Start] button to begin the updating
Step 14: Select the right “.bin” file.
Step 15: The Ultima gives a beep and "Connection with ULTIMA established! Please wait..." is shown in
the update tool.
Step 16: After 13 seconds the message "Sending firmware to ULTIMA!! Please wait...!" appears in the
update tool.
Step 17: The progress bar now starts increasing.
73 AP-74050, Rev : 1.1

Step 18: The first seconds the progress bar colours red and green. Afterwards the progress bar is black.
Notes :
Please note that you passed the critical section of updating when the progress bar is black.
When the machine is shut down in the critical section of the update we refer to the section
“When you shut down the Ultima inside the critical section”.
Step 19: After 1 minute the update finishes with the text "Firmware update successful, restart the
ULTIMA!" on the Ultima update tool.
Step 20: Power OFF the Ultima cutting plotter.
Notes :
Please perform a “Code Update” after a firmware upgrade. Without performing a “Code
Update”, the panel keyboard remains in the old firmware version.
Step 21: Restart the Ultima cutting plotter.
6.4.2. Installation of new firmware with the serial cable
To install new firmware using a serial cable, please follow the instructions below.
Step 2: Connect the Ultima cutting plotter with your PC by a serial cable.
Step 4: Check the Ultima comport settings. Go to the communication menu and check following items :
• Baud rate : 9600 Baud
• Databits : 8
• Parity : None
• Stop Bits : 1
• Flow control : Softw
Updating is only possible with these settings!

We chose 9600 Baud to update at a relative high speed.
Step 6: Select the right comport, the number labelled at your PC connection (COMXX).
Step 7: Press the [connect] button.
Step 9: Press [Start] to begin the update.
Step 10: Select the correct “.bin” file.
the update tool.
74 AP-74050, Rev : 1.1

update tool.
Notes :
Please note that you passed the critical section of updating when the progress bar is
black. When the machine is shut down in the critical section of the update we refer to
the section “When you shut down the Ultima inside the critical section”.
Step 15: After 10 minutes the update finishes with the text "Firmware update successful, restart the
Notes :

6.4.3. Installation of new firmware a flash card
To install new firmware using a flash card, please follow the instructions below.
Step 2: Insert the flash card at the rear side of the Ultima cutting plotter.
Step 4: After copying the firmware you hear a short beep. The Ultima cutting plotter starts verifying the
firmware.
Notes :
In case you do not hear a short beep, you have to restart the Ultima cutting plotter.
Step 5: After verifying, the Ultima cutting plotter starts to produce continuously a beep.
Notes :

75 AP-74050, Rev : 1.1

6.5. PERFORMING A CODE UPDATE
To perform a code update, please follow the instructions mentioned below.
Notes :
Let the unit perform the initialise routine (determination of left and right borders). In case
media is loaded media will also be measured.
Step 2: Press the [PRESETS], [ORIGIN], [SPEED] and [FORCE] key simultaneously.
Step 3: The display on the Operation Panel shows following message:
Code update
Please wait …
Step 4: The display on the Operation Panel shows (for a second) the message mentioned below and
returns to the start-menu.
Mutoh Europe NV
Version x.xx
Initializing
Please wait
76 AP-74050, Rev : 1.1

6.6. WHEN YOU SHUT DOWN THE ULTIMA OUTSIDE THE

CRITICAL SECTION
Notes :
If the Ultima was powered OFF outside the critical section, it is only possible to update
the Ultima by using the serial cable. Please refer to the section “Installation of new
firmware with the serial cable”.
Step 2: Connect the Ultima cutting plotter with your PC by a serial cable.
Step 4: Check the Ultima comport settings. Go to the communication menu and check following items :
• Baud rate : 9600 Baud
• Databits : 8
• Parity : None
• Stop Bits : 1
• Flow control : Softw
Updating is only possible with these settings!

We chose 9600 Baud to update at a relative high speed.
Step 6: Select the right comport, the number labelled at your PC connection (COMXX).
Step 7: Press the [connect] button.
Step 10: Press [Start] to begin updating.
Step 11: Select the correct “.bin” file.
Step 12: Power ON the Ultima cutting plotter. Please note that you have to do it within 10 seconds.
the update tool.
Notes :
If there was not a beep restart the updating procedure.
update tool.
77 AP-74050, Rev : 1.1

Notes :
Please note that you passed the critical section of updating when the progress bar is
black. When the machine is shut down in the critical section of the update we refer to
the section “When you shut down the Ultima inside the critical section”.
Step 17: After 10 minutes the update finishes with the text "Firmware update successful, restart the
Notes :

78 AP-74050, Rev : 1.1

6.7. WHEN YOU SHUT DOWN THE ULTIMA INSIDE THE

CRITICAL SECTION
Notes :
If the Ultima was powered OFF inside the critical section, it is only possible to update the
Ultima by using a flash card. Please refer to the section “Installation of new firmware
with a flash card”.
79 AP-74050, Rev : 1.1

6.8. HOW TO PERFORM A PARAMETER BACKUP
Before changing a board, it is possible to save the user settings, machine settings and preset settings onto a
parameter backup card. So after installation of a new board you can transfer the user settings, machine
settings and preset settings to the unit.
To perform a parameter backup, you can use the flashcard with the special label “Ultima Parameter Backup
Card”.
Use the Dipswitch 2.1 to choose between “backup” and “recover”.
DSW2.1 = ON Recover parameters stored on backup card

DSW2.1 = OFF Store parameters to backup card
6.8.1. Saving the settings onto the parameter backup card
Step 1: Insert the parameter backup card in the board.
Step 2: Power ON the unit.
Step 3: Select save with the [UP] key
SAVE ← [UP] key
RECOVER ← [DOWN] key
Step 4: Following message appears on the display.
Saving data
to backup flash
card (OBF→ PCCF) v1.0
please wait …
Step 5: After a few seconds following message appears on the display.
Saving data
to backup flash
card (OBF→ PCCF) v1.0
is done …
Step 6: The user settings, machine settings and preset settings are stored onto the parameter backup
card.
Step 7: Power OFF the unit.
Step 8: Now you are ready to change the board.
80 AP-74050, Rev : 1.1

6.8.2. Saving the settings from the parameter backup card onto the
board
Step 1: Insert the parameter backup card in the board.
Step 2: Power ON the unit.
Step 3: Select recover with the [DOWN] key.
SAVE ← [UP] key
RECOVER ← [DOWN] key
Step 4: Following message appears on the display.
Saving data
to backup flash
card (PCCF → OBF) v1.0
please wait …
Step 5: After a few seconds following message appears on the display.
Saving data
to backup flash
card (PCCF → OBF) v1.0
is done …
Step 6: The user settings, machine settings and preset settings are stored onto the parameter backup
card.
Step 7: Power OFF the unit.
Step 8: The new board contains the previously saved user settings, machine settings and preset
settings.
Notes :
PCCF = Personal Computer Card Flash

OBF = On Board Flash
81 AP-74050, Rev : 1.1

6.9 OFFSET ADJUSTMENT
Notes :
• One of the most important factors to obtain good quality, but unfortunately also one
of the factors that is easily forgotten, is the offset.
• For a correct offset please refer to the User’s Guide
82 AP-74050, Rev : 1.1

7. JIG TOOL LIST
7.1. JIG TOOL LIST
PART NAME PART#

Adjustment Pen 10 g JD-41440
Bar tension gauge 50 g JD-41446A
Bar tension gauge 500 g JD-41446B
Bar tension gauge 5 kg JD-41446C
Pressure measurement attachment JD41563
Steel belt tension attachment JD-41565
L shaped Allen key 1.27 mm (1/20”)
+ Screw driver (Philips) #1
+ Screw driver (Philips) #2
- Screw driver
Open wrench 13 mm
Box wrench 13 mm
7.2. SPECIAL GLUE
External screw locking glue : LOCTITE 7400 (VERNISTOP)

Screw thread locking glue : LOCTITE 243
Glue for fixing Y)motor pulley : LOCTITE 406
83 AP-74050, Rev : 1.1

84 AP-74050, Rev : 1.1

8. PARTS LISTS ULTIMA

8.1. BODY AND COVERS
Ref. Description Partnumber Qty

- Final assy SR25 MY-SR25-15000 1
Final assy SR47 MY-SR47-15000 1
1 Aging-level SR25 MY-SR25-14000 1
Aging-level SR47 MY-SR47-14000 1
2 Y-rail cover assy SR25 MY-25340 1
Y-rail cover assy SR47 MY-25347 1
3 DIN 7985 M4x6 BM-1400-004006 4
4 Universal keyboard assembly MY-20405 1
5 DIN 7981 C ST2.9x9.5 BM-2102-129905 4
6 Doorvoertule art # 042 2200 699 07 BR-18002 1
7 Right Cover Assy Ultima MY-25872 1
8 Left Cover Assy Ultima MY-25873 1
9 Bind Small Screw M4x8 NS-11040081 4
10 Countersunk Screw M4x10 Nickel Coated NS-51040101 4
85 AP-74050, Rev : 1.1

8.2. KEYBOARD ASSY

1 Universal Keyboard Assembly MY-20405 1
- Keyboard Foot Assy MY-20402 1
2 Foot Universal Keyboard ME-20402 1
3 Hinge Universal keyboard ME-20403 1
4 Release Button Universal Keyboard ME-20405 1
5 Spring Keyboard ME-20406 1
6 Spring PIN L35 D4 BR-040035 2
- PCB Assy Universal Keyboard EY-20405 1
7 ARROW Key Universal Keyboard ME-20404 1
8 PCB Universal Keyboard Soldered EP-20405 1
9 LCD Spacer DE-43797 4
10 LCD Display 4 Lines x 16 char ML-1005 1
11 Bottom Universal Keyboard ME-20400 1
12 Keyboard Sheet SR LB-25300 1
13 Cover Universal Keyboard ME-20401 1
14 Plastite 3x10 ELVZ BM-2400-103010 6
86 AP-74050, Rev : 1.1

8.3. AGING LEVEL

- Aging Level SR25 MY-SR25-14000 1
Aging Level SR47 MY-SR47-14000 1
1 Base Plate Assy SR25 MY-SR25-13000 1
Base Plate Assy SR47 MY-SR47-13000 1
2 Penhead Assy MY-25475 1
3 Rear Plate Assy SR25 MY-25320 1
Rear Plate Assy SR47 MY-25327 1
4 Cap Screw M3x6 DR-4001-43923 11
5 Front Plate Assy SR25 MY-25330 1
Front Plate Assy SR47 MY-25337 1
6 Pressure Flat Spring DE-47523 1
7 Penhead Screw M4x8 DR-4001-43396 1
8 PCB Penhead Cable Assy Ultima MY-25371 1
9 Cap Screw M3x4 DR-4001-43993 2
10 Penhead Cover Ultima ME-25480 1
11 Cap Screw M2x12 Nickel Coated NS-06020121 1
87 AP-74050, Rev : 1.1

8.4. PENHEAD ASSY

- Penhead Assy SR MY-25475 1
1 Base Grijparm Assy SR MY-25475D 1
2 Penhead Base Assy MY-20864A 1
3 Grijparm vast mes SR MY-25475C 1
4 Bridge anti-play MY-20864B 1
5 Linear Scale for Head DE-45203 1
6 Sim for linear scale DE-45204 1
7 Tension spring DE-44208 1
8 Coil assy penhead EY-46781 1
9 Yoke assy DE-46874 1
10 Bracket cutter holder SR ME-25477 1
11 Cutter holder assy MY-25476 1
12 E-pos assy penhead SR MY-25478 1
88 AP-74050, Rev : 1.1

8.5. CUTTER HOLDER ASSY

- Cutter holder assy MY-25476 1
1 Cutter holder reworked ME-25476 1
2 Cutter holder Japan DE-21476 1
3 Work on DE-21476 Cutter holder WR-25476 1
4 Cutter spring DF-40936 1
5 Cutting blade DF-40820 1
6 Solenoid assy DE-33659 1
7 Solenoid spring DE-49194 1
8 Cutter Cap PE DF-40853 1
9 Plate nut DE-42544 1
10 Bind Small Screw M3x6 NS-11030061 1
89 AP-74050, Rev : 1.1

8.6. LASER-EPOS ASSY PENHEAD

- E-pos assy Penhead SR MY-25478 1
1 E-pos blokje Penhead SR ME-25478 1
2 Laser Led Arach LDLM713 ML-1021 1
3 E-pos ML-1023 1
90 AP-74050, Rev : 1.1

8.7. BASE PLATE ASSY

- Base Plate Assy SR25 MY-SR25-13000 1
Base Plate Assy SR47 MY-SR47-13000 1
1 Mechanicals final assy SR25 MY-SR25-12000 1
Mechanicals final assy SR47 MY-SR47-12000 1
2 Base Assy SR25 MY-25350 1
Base Assy SR47 MY-25357 1
3 Spacer PA D5xd3.IxH5 BR-40503 2
4 DIN 7985 M3x12 ELVZ BM-1400-003012 2
5 Spacer 2 x Thread M3x25x7 BR-80325 4
6 Cap Screw M3x6 DR-4001-43923 4
7 PCB Keyb Tsprint assy Ultima EY-25372 1
8 DIN 7500C Taptite M3x6 ELVZ BM-1400-103006 6
9 Screw Plate for keyboard cable ME-25352 1
10 Coiled cable 6 way 3M dummy MK-41020 1
11 Cable main → Subkeyb Ultima MK-61025 1
91 AP-74050, Rev : 1.1

8.8. BASE ASSY

- Base assy SR25 MY-25350 1
Base assy SR47 MY-25350 1
1 Base plate SR25 ME-25350 1
Base plate SR47 ME-25350 1
2 AC – inlet LC MS-1050 1
3 P/S Ultima LED 150 F – 0524 – SN EY-25375 1
4 Cap screw M3x6 DR-4001-43923 14
5 PCB main board assy Ultima EY-25370 1
6 Screw Plate PCB Unit ME-25351 1
7 Cable guide AE-91065 1
8 Power supply cable Ultima MK-51525 1
92 AP-74050, Rev : 1.1

8.9. MECHANICALS FINAL ASSY

- Mechanicals final assy SR25 MY-SR25-12000 1
Mechanicals final assy SR47 MY-SR47-12000 1
1 XY-motor assy SR25 MY-SR25-11000 1
XY-motor assy SR47 MY-SR47-11000 1
2 T-bush BR-10010 2
3 T-spacer BR-40010 2
4 Pressure shaft for SC-650 ME-20777 1
Pressure shaft for SC-1300 ME-21277 1
5 DIN 6799 #7 BR-31070 2
6 Lever assy SR MY-25310 1
7 Sensor Bracket ME-20622 1
8 DIN 7500C Taptite M3x6 ELVZ BM-1400-103006 2
9 Cap screw M3x6 DR-4001-43923 2
10 DIN 7500C Taptite M4x15 LEVZ BM-1400-104016 2
11 Lever Sensor assy EY-41720 1
12 Cable guide AE-91065 2
13 Suction tube assy SR25 MY-25390 1
Suction tube assy SR47 MY-25397 1
14 DIN 7981C ST2.9x9.5 BM-2102-129905 4
93 AP-74050, Rev : 1.1

8.10. SUCTION TUBE ASSY

- Suction tube assy SR25 MY-25390 1
Suction tube assy SR47 MY-25397 1
1 Suction tube SR25 ME-25390 1
Suction tube SR47 ME-25397 1
2 Fan Type 4484F DE-32444B 1
3 Fan Grid ME-20668 1
4 DIN 7985 M4x35 ELVZ BM-1400-004035 4
5 Mousse Suction tube ME-25391 1
94 AP-74050, Rev : 1.1

8.11. LEVER ASSY

- Lever assy SR MY-25310 1
1 Pressure lever SR ME-25310 1
2 Bush DE-44782 4
3 Shaft 2 pressure lever (long) SR25 ME-25312 1
4 Yoke ME-20626 1
5 Shaft 1 Pressure lever (short) SR25 ME-25311 1
6 Pressure link ME-20625 1
7 Pressure lever knob DE-32692 1
8 Cap screw M3x6 Nickel Coated NS-06030061 1
95 AP-74050, Rev : 1.1

8.12. XY-MOTOR ASSY

- XY-motor assy SR25 MY-SR25-11000 1
XY-motor assy SR47 MY-SR47-11000 1
1 XY-assy SR25 MY-SR25-10000 1
XY-assy SR47 MY-SR47-10000 1
2 Y-motor bracket ME-20606 1
3 DIN7981C ST3.5x25 BM-2100-135025 5
4 DIN7500C Taptite M3x6 ELVZ BM-1400-103006 4
5 Y-return ME-20607 1
6 Y-drive pulley assy SC MY-47657 1
7 Y-return pulley assy SC MY-47675 1
8 Belt cam assy SC-650 MY-20661 1
Belt cam assy SC-1300 MY-21761 1
9 DIN 7985 M3x30 ELVZ DR-4001-45094 1
10 X-motor pulley assy EY-10000 1
11 Penhead screw M3x10 DR-4001-43475 4
12 Y-motor assy EY-10010 1
13 Grid pulley DE-46555 1
14 Setscrew DIN914 M3x3 BM-6906-203003 2
15 Speed reduction belt DE-47079 1
16 Timing belt DE-44157 1
17 Feet Y-pulley DE-47091 2
96 AP-74050, Rev : 1.1

8.13. BELT-CAM

- Belt-cam assy SC-650 MY-20661 1
Belt-cam assy SC-1300 MY-21761 1
1 Y-drive belt SC-650 ME-20661 1
Y-drive belt SC-1300 ME-21761 1
2 Belt cam for SC S2M Belt ME-10107 1
3 Belt cam SM ME-10108 2
4 Cap screw M3x6 DR-4001-43923 4
97 AP-74050, Rev : 1.1

8.14. Y-DRIVE PULLEY

- Y-drive pulley assy SC MY-47657 1
1 Shaft drive pulley for SC ME-20059 1
2 DIN 6799 #5 BR-31050 3
3 Bearing DE-47095 2
4 Y-speed reduction pulley DE-47057 1
98 AP-74050, Rev : 1.1

8.15. Y-RETURN PULLEY ASSY

- Y-return pulley assy SC MY-47675 1
1 Y-return pulley shaft ME-20058 1
2 DIN 6799 #5 BR-31050 3
3 Bearing DE-47095 2
4 Y return pulley DE-47075 1
5 DIN 705A/916 Adj Ring 6x12x8 BR-32000 1
6 DIN 7985 M3x30 ELVZ DR-4001-45094 2
99 AP-74050, Rev : 1.1

8.16. X-MOTOR PULLEY ASSY

- X-motor pulley assy EY-10000 1
1 X-motor SC EE-10000 1
2 Pulley motor DE-46568 1
100 AP-74050, Rev : 1.1

8.17. Y-MOTOR PULLEY ASSY

- Y-motor pulley assy EY-10010 1
1 Y-motor SC EE-10010 1
2 Pulley motor DE-48990A 1
101 AP-74050, Rev : 1.1

8.18. XY ASSY

- XY-assy SR25 MY-SR25-10000 1
XY-assy SR47 MY-SR47-10000 1
1 Right end plate assy Ultima MY-25370R 1
2 Y-rail assy SR25 MY-2530-10401 1
Y-rail assy SR47 MY-2537-10401 1
3 X-rail assy SR25 MY-2530-10400 1
X-rail assy SR47 MY-2537-1400 1
4 DIN7981C ST3.5x25 BM-2100-135025 6
5 DIN7981C ST4.2x25 BM-2100-142022 8
6 Left end plate assy Ultima MY-25370L 1
7 Paper sensors assy LC MY-25016 1
8 Cap screw M3x4 DR-4001-43993 1
102 AP-74050, Rev : 1.1

8.19. X-RAIL ASSY

- X-rail assy SR25 MY-2530-10400 1
X-rail assy SR47 MY-2537-10400 1
1 X-rail SR25 ME-25300 1
X-rail SR47 ME-25307 1
2 Bearing holder assy LC MY-25010 8
3 Drive shaft SC-650 ME-20609 1
Drive shaft SC-1300 ME-21611 1
4 Screw plate DR-2164-41836 9
5 Hexagon Socket Bolt M4x8 DR-4008-44543 16
6 Grid roller 136mm diff small th 26 + setscrews DE-46550B 1
7 Grid roller 14mm + setscrews DE-44142 5
8 Spacer d8.5/d7 L10 BR-40710 2
9 Cutting mat LC ME-23310 1
10 Set plate DE-45118 1
11 Pan head screw M4x8 DR-4001-43396 1
103 AP-74050, Rev : 1.1

8.20. BEARING HOLDER ASSY

1 Bearing holder assy LC MY-25010 1
2 Bearing holder base LC ME-25010 1
3 Bearing holder cover LC ME-25011 1
4 Roller DE-46552 1
5 Plastite 3x10 ELVZ BM-2400-103010 2
104 AP-74050, Rev : 1.1

8.21. Y-RAIL ASSY

- Y-rail assy SR25 MY-2530-10401 1
Y-rail assy SR47 MY-2537-10401 1
1 Y-rail SC-650 ME-10421 1
Y-rail SC-1300 ME-10424 1
2 Grid Indicator ME-20028 5
4 Screw plate DR-2164-41836 4
5 DIN 912 Standard M4x6 ELVZ BM-6000-604006 4
6 Pressure Roller + Jumper SC/MC MY-10403 1
7 Pressure Roller SC/MC MY-10402 1
105 AP-74050, Rev : 1.1

8.22. PRESSURE ROLLER ASSY

1 Pressure roller assy MY-10403 1
2 Pressure roller assy without position indicator MY-10402 1
3 Pressure base ME-20030 1
4 Pressure cam ME-20032 1
5 Pressure arm ME-20031 1
6 Pressure roller shaft ME-2033 1
7 Pressure roller DE-44190 1
8 Pressure hinge shaft ME-20613 1
9 Asborgring 3.2 BR-31032 2
10 Spring conn. Shaft ME-2034 1
11 T-spacer insul. Sleeve BR-1013 1
12 Spring shaft ME-20611 1
13 Asborgring 6 BR-31060 1
14 Vlakke sluitring M8 BR-14338 2
15 Pressure spring ME-10096 1
16 Hex nut M8 BM-9104-108004 2
17 Position indicator ME-20029 1
106 AP-74050, Rev : 1.1

8.23. PAPER SENSORS ASSY

- Paper sensors assy LC MY-25016 1
1 Sensor Bracket LC ME-25016 1
2 Photo IC sensor E-PS-R50LA 2
3 DIN 7985 M3x10 ELVZ BM-1400-003010 2
107 AP-74050, Rev : 1.1

8.24. LEFT END PLATE ASSY

- Left end plate assy Ultima MY-25370L 1
1 Frame left endplate ME-25370L 1
2 Speed nut ST2.8 nul 517-1 BR-90028 4
3 Cover support 2 ME-20636 2
4 DIN 7985 3x6 ELVZ BM-1400-003006 2
108 AP-74050, Rev : 1.1

8.25. RIGHT END PLATE ASSY

- Right end plate assy Ultima MY-25370R 1
1 Frame right endplate ME-25370R 1
2 Speed nut ST2.8 nul 517-1 BR-90028 4
3 Cover support 2 ME-20636 2
4 DIN 7985 M3x6 ELVZ BM-1400-003006 2
109 AP-74050, Rev : 1.1

110 AP-74050, Rev : 1.1

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Maintenance Manual

MUTOH EUROPE N.V. AP-74050, Rev.: 1.1

COPYRIGHT © 2003 Mutoh Europe N.V. all rights reserved.

Change the direction of your radio and TV reception antenna or feeder.

Change the direction of the cutter.

3 AP-74050, Rev : 1.1

2. SYSTEM BLOCK DIAGRAM .....................................................................................................15

5 AP-74050, Rev : 1.1

6. PARTS REPLACEMENT AND ADJUSTMENT ........................................................................51

7. JIG TOOL LIST.............................................................................................................................83

8. PARTS LISTS Ultima ...................................................................................................................85

6 AP-74050, Rev : 1.1

7 AP-74050, Rev : 1.1

• This is a Class A product approved for industrial environments. In a domestic

1.2. IMPORTANT NOTE

9 AP-74050, Rev : 1.1

1.3. SPECIFICATIONS OF THE ULTIMA CUTTING PLOTTER

Specifications ULTIMA SC-850D ULTIMA SC-1400D

10 AP-74050, Rev : 1.1

1.4. ULTIMA CUTTING PLOTTER, ENVIRONMENT

• Avoid unnecessary vibrations and set up your cutter on a level surface.

11 AP-74050, Rev : 1.1

1.5. FUNCTION KEYS

5) UP : Press the [UP] key to increase the value of the setting.

8) ORIGIN : Press the [ORIGIN] key to change the origin.

12 AP-74050, Rev : 1.1

13 AP-74050, Rev : 1.1

14 AP-74050, Rev : 1.1

2. SYSTEM BLOCK DIAGRAM

2.1. BLOCK DIAGRAM SC-850D

15 AP-74050, Rev : 1.1

2.2. BLOCK DIAGRAM SC-1400D

16 AP-74050, Rev : 1.1

3.1. SERIAL INTERFACE RS-232C (STANDARD)

1) Baud rate (software selectable)

2) Data length (software selectable)

3) Stop bits (software selectable)

4) Parity (software selectable)

7) RS-232C driver / receiver IC

17 AP-74050, Rev : 1.1

3.1.1. RS-232 pin configuration

PIN # SIGNAL Abbr. Signal direction

3.1.2. Serial cable configuration

Computer side : DB-25F Cutter side : DB-9M

Cable length: 3 meter

18 AP-74050, Rev : 1.1

3.2. USB INTERFACE

3.2.1. USB pin configuration

19 AP-74050, Rev : 1.1

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4.1. RECOVERABLE ERRORS

Recoverable errors are mostly related to communication problems or user mistakes.

2) Media is loaded, but the cutter does not operate.

5) Some parts of the design are not well cut.

21 AP-74050, Rev : 1.1

4.2. UNRECOVERABLE ERRORS

The machine will stop working when an unrecoverable error occurs.

Refer to the following chart for error code explanation :

NOYENCODER : No Y encoder, check connectors or call service.

KEYB_COMM_CHECKSUM : KEYB communication checksum problem

PGTOOSHORT : PG error : Media too short to perform a 'PG;'.

22 AP-74050, Rev : 1.1

4.3. PROBLEM SYMPTOMS AND SUGGESTED ACTIONS

4.3.1. Processor errors