AP74035 Rev1,0 PDF

MAINTENANCE MANUAL
JUNIOR PLUS CUTTING PLOTTER

(+ JUNIOR 24 CUTTING PLOTTER)
st
Mutoh Europe N.V. AP-74035, Rev : 1.0 21 June 2001
2 AP-74035, Rev 1.0 – 21 June 2001
COPYRIGHT NOTICE
COPYRIGHT ã 2001 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 Junior Cutter. 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 :
1. 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.
2. 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.
FCC WARNING
This equipment complies with 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 reception or operation or 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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Service Manual – Junior Plus (Junior 24)
TABLE OF CONTENTS :
1.SPECIFICATIONS...........................................................................................................................7
1.1 Introduction................................................................................................................................7
1.2 Junior Plus..................................................................................................................................7
1.3 Junior 24.....................................................................................................................................7
1.4 Working Conditions...................................................................................................................8
1.5 Parts............................................................................................................................................9
1.5.1 What’s in the box? ..............................................................................................................9
1.5.2 Getting to know the cutter parts........................................................................................11
1.5.3 Control Panel JUNIOR PLUS...........................................................................................17
1.5.4 Control Panel JUNIOR 24 ................................................................................................19
1.5.5. System Block Diagram Junior Plus. ................................................................................20
1.5.6. System Block Diagram Junior 24. ...................................................................................21
2.TROUBLESHOOTING..................................................................................................................23
3.MAINTENANCE ...........................................................................................................................25
3.1 Introduction..............................................................................................................................25
3.2 Connecting the cutter ...............................................................................................................26
3.3 Connecting the power cable.....................................................................................................27
3.4 Blade worn or broken...............................................................................................................28
3.5 Cover Left : removal and installation. .....................................................................................29
3.6 Cover Right : removal and installation. ...................................................................................29
3.7 Y - rail : removal and installation. ...........................................................................................29
3.8 PCB Plate : removal and installation. ......................................................................................30
3.9 X- motor : removal and installation. ........................................................................................31
3.10 Y- motor : removal and installation. ......................................................................................32
3.11 Steel belt : removal and installation.......................................................................................33
3.12 Mainboard ..............................................................................................................................34
3.13 Adjustment with the Cutting Plotter ‘ON’.............................................................................35
3.14 How to correctly install new firmware?.................................................................................36
4.DIAGNOSTIC MODE ...................................................................................................................39
4.1 How to get in Diagnostic Mode? .............................................................................................39
4.2 Adjustment of the x and Y axis :..............................................................................................39
4.3 Control of the sensors. .............................................................................................................39
4.4 Check the Encoder. ..................................................................................................................39
4.5 Check the Head movement. .....................................................................................................40
4.6 Check the keyboard..................................................................................................................40
4.7 Check the connector and battery in the Ram-card. ..................................................................40
5.SOFTWARE : JUNIOR PLUS. ......................................................................................................41
5.1 Installation of the software.......................................................................................................41
5.1.1 How to install Mutoh JuniorCut?......................................................................................42
5.1.2 How to install Mutoh Setup Junior Series Software? .......................................................42
5.1.3 Checking communication with the Junior Plus Cutting Plotter........................................43
5.2 Junior Plus setup program – control panel overview...............................................................45
5.3 Junior (24) setup program – control panel overview ...............................................................49
5.4 Using the Software...................................................................................................................53
6.EXPLODED VIEW JUNIOR PLUS ..............................................................................................57
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1.SPECIFICATIONS
1.1 Introduction.
This section describes the specifications of this machine.
1.2 Junior Plus.

Max. Media Width 650mm
Max. Cutting Area 600mm x 4m
Max. Media Thickness 1mm
Speed Max.848mm/s
Pressure Range 20 – 250 g
Interface Serial RS-232
Input Buffer 512Kb / 1Mb
Roll Transport System Integrated
Stand Optional
Graphic Language MH-GL/2 (HP-GL/2 Compatible)
· Axial Speed from 450 to 848 mm/s.

· Acceleration 1.5G reached in 0.5 seconds.
· LCD screen à NO.
· Direct speed dial à Yes.
· Throughput boost via integrated smoothing.
· Integrated keyboard with ONLINE control features.
· Quality (50%) – Normal – Draft (200%).
· Force adjustment : -80% and +80%.
· Integrated contour cutting support.
· Remote control and configuration.
· Firmware available via the web
1.3 Junior 24.

Max. Media Width 650mm
Max. Cutting Area 600mm x 4m
Max. Media Thickness 1mm
Speed Max.636mm/s
Pressure Range 20 – 250 g
Interface Serial RS-232
Input Buffer 10kB – Max. 1Mb
Roll Transport System Integrated
Stand Optional
Graphic Language MH-GL/2
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1.4 Working Conditions
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 40°C (41°F to 104°F)

§ Humidity : 35% - 75% non-condensing
o Recommended environment
§ Temperature : Room temperature 16°C to 32°C (61°F to 90°F)

§ Humidity : 50% - 65% non-condensing
o Variation rate
§ Temperature : 2°C per hour

§ Humidity : 5% per hour
o Storage environment
§ Temperature : 0°C to 50°C (32°F to 122°F)
· 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 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 50cm in front and 50cm at the rear. It is recommended
to place the front of the cutter at the edge of a table, as shown in the illustration below. This is to avoid the
media from bumping against the table surface.
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1.5 Parts
1.5.1 What’s in the box?
Contents of the Junior Plus plotter box :
A. JUNIOR Plus cutting plotter unit.
B. MUTOH Junior Plus Cutter User’s Guide.
C. One knife holder with pre-mounted cutting blade.
D. Set of 2 spare cutting blades and 1 spring for cutting jobs (45°/Offset 0.50 mm).
E. Set of 2 water-based fibre-tip pens.
F. Spare cutting mat.
G. Power cord.
H. RS-232 interface cable.
I. RS-232 adapter cable (DB 9 / DB 25).
J. Set of 2 conveyor rollers.
K. Set of 2 guiding profiles for the conveyor rolls.
L. JuniorCut Software
Note :
A cutting plotter stand for the Junior Plus cutter is available as an option.
9 AP-74035, Rev 1.0 – 21 June 2001

Contents of the Junior 24 plotter box :
A. JUNIOR cutting plotter unit.
B. Junior User’s Guide.
C. One knife holder with pre-mounted cutting blade.
D. Set of 2 spare cutting blades and 1 spring.
E. Set of 2 water-based fibre-tip pens.
F. Spare cutting mat.
G. Power cord.
H. RS-232 interface cable.
I. RS-232 adapter cable (DB 9 / DB 25).
J. Set of 2 conveyor rollers.
K. Set of 2 guiding profiles for the conveyor rolls.
L. JuniorCut Software
Note :
A cutting plotter stand for the Junior 24 cutter is available as an option.
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1.5.2 Getting to know the cutter parts.
The JUNIOR PLUS cutter is illustrated below. The indicated parts are explained in the table on the next
pages.
12 11 10 1
5 6
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Part Description
1. Control Panel Panel with indicator LED’s and control push buttons.
2. Power switch Switches the cutting plotter ‘ON’ or ‘OFF’.
3. Pressure hold levers Raise and lower the pressure rollers. Lowering the pressure rollers will
hold the media in place.
4. Media guiding base Device with ninja wheels to hold the media down.
5. Platen & Grid cover Supports the cutting media and guides the movement of the media along
the X-axis (Forward/Backward).
6. Cutting Mat Provides a reliable cutting surface and minimises damage to the knife tip.
7. Serial Interface RS-232 serial interface connector to connect the cutter to the host
Connector computer.
8. Slot for optional RAM flash card slot to supply the unit with an optional input buffer of 256
input buffer kB / 512 kB / 1Mb or to upgrade the cutter firmware.
9. Power connector Connector for the power cord, which plugs into the main power supply of
the cutter.
10. High Precision All available tools such as knife holders, drawing pens and painting pens
Single Tool Head can be secured into the head using the clip. The tool head moves along
the Y-axis to the exact cutting position. (Left / Right)
11. Drive Rollers Move the cutting media along the X-axis (Forward/Backward).
12. Pressure Rollers Hold the media against the drive rollers during media transport or cutting.
13. Roll support system The roll support system carries the conveyor rollers.
14. Conveyor rollers When using roll media for cutting jobs, put the roll of media on top of the
two conveyor rollers.
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The JUNIOR 24 cutter is illustrated below. The indicated parts are explained in the table on the next pages.
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Part Description
1. Control Panel Panel with indicator LEDs and control turning knobs.
2. Power switch Switches the cutting plotter ON or OFF.
3. Pressure hold levers Raise and lower the pressure rollers. Lowering the pressure
rollers will hold the media in place.
4. Media guiding base Device with ninja wheels to hold the media down.
5. Platen & Grid cover Supports the cutting media and guides the movement of the
media along the X-axis (Forward / Backward).
6. Cutting Mat Provides a reliable cutting surface and minimises damage to the
knife tip.
7. Serial Interface Connector RS-232 serial interface connector to connect the cutter to the host
computer.
8. Slot for optional input buffer RAM flash card slot to supply the unit with an optional input buffer
of 256 kB / 512 kB / 1 Mb or to upgrade the cutter firmware.
9. Power Connector Connector for the power cord, which plugs into the main power
supply of the cutter.
10. High Precision Single-Tool Head All available tools such as knife holders, drawing pens and
painting pens can be secured into the head using the clip. The
tool head moves along the Y-axis to the exact cutting position.
(Left / Right)
11. Drive Rollers Move the cutting media along the X-axis (Forward / Backward).
12. Pressure Rollers Hold the media against the drive rollers during media transport or
cutting.
13. Roll support system The roll support system carries the conveyor rollers.
14. Conveyor rollers When using roll media for cutting jobs, put the roll of media on top
of the two conveyor rollers
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1.5.3 Control Panel JUNIOR PLUS
1. SPEED CONTROL BUTTON
Ø Draft = selected speed X 2
Ø Normal = selected speed
Ø Quality = selected speed / 2
2. FORCE CONTROL BUTTON
Ø Leftmost LED = selected force –80%
Ø Central LED = selected force
Ø Rightmost LED = selected force +80%
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Furthermore, the user is informed about the current status of the cutter by 3 LEDs :
3. POWER ON/OFF LED à green
4. READY / DATA receive LED à orange

OFF Þ OFF-LINE status
ON Þ ON-LINE status =
READY to receive data
FLASHING Þ receiving DATA from the
host computer
5. ERROR LED à red

When the error led starts lighting, switch the power
of the junior cutting plotter ‘OFF’ and start again.
Caution :
When you want to restart the JUNIOR Plus cutting plotter please make sure to wait until
the POWER ON led goes out.
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1.5.4 Control Panel JUNIOR 24
The control panel contains two turning knobs:

1. SPEED CONTROL KNOB
2. FORCE CONTROL KNOB
Furthermore, the user is informed about the current status of the cutter by 3 LEDs:
3. POWER ON / OFF LED _ green
4. READY / DATA receive LED _ orange

- OFF _ OFF-LINE status
- ON _ ON-LINE status = READY to receive data.
- FLASHING _ receiving DATA from host computer.
5. ERROR LED _ red
When the error led starts lighting, switch the power of the junior cutting plotter ‘OFF’ and start again.
Caution :
When you want to restart the JUNIOR Plus cutting plotter please make sure to wait until
the POWER ON led goes out.
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1.5.5. System Block Diagram Junior Plus.
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1.5.6. System Block Diagram Junior 24.
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2.TROUBLESHOOTING
Recoverable errors
Recoverable errors are mostly related to communication problems or user mistakes.
These kind of errors can appear while the machine is working or sometimes it makes the machine stop but
starts again when error is corrected.
Unrecoverable errors
Unrecoverable errors make the machine stop.
To clear the error message, the machine needs to be powered OFF and ON again. (Wait +/- 10 seconds
between power OFF / ON).
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Problem Isolation
PROBLEM POSSIBLE CAUSE SUGGESTED

DESCRIPTION ACTIONS
System is dead, no movement. Defective Power supply (P/S). Check Power Cord.
Check wall outlet.
Check fuse on P/S.
Replace P/S
Defective Main Board. Replace Main Board.

Power LED ‘ON’, but no Defective Main Board. Replace Main Board.
movement of motors and Check cable connections.
cutting head.
Plotter does not shuffle media. Media sensors dusty or bad. Clean or replace media sensors.
Plotter has shuffled media but Plotter is Off-line. Put plotter in ON-line.
does not respond to data.
Interface cable not connected or Check interface cable.
bad.
Bad interface port. Check port or replace Main Board.
COM-port setting wrong. Select right COM-port.

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 to far out. Adjust knife depth.
Cutting force is to high. Reduce cutting force.
Cutting mat is worn. Replace cutting mat.
Play on cutting head. Check or replace cutting head.

Media tracking problems. Media is not loaded straight in the Load Media again.
machine.
Media skews during cutting or Grid rolls are dirty. Clean grid rollers.
loading.
Grid rollers or pressure rollers Replace grid rollers or pressure
worn. rollers.
Pressure on pressure rollers not Replace pressure roller springs.

equal.
Media backing is very slippery. Change media type.
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3.MAINTENANCE
3.1 Introduction
Warning :
Before working on the machine, always switch the machine OFF and pull out the
power supply plug. Otherwise you may suffer an electrical shock.
Note :
To install, reverse the removal procedure.
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3.2 Connecting the cutter
With a 2-way serial RS-232C interface you make the connection between the cutter and the computer.
The serial RS-232C interface enables the cutter to be connected to and controlled by an RS-232C
compatible host computer system. The cutter is equipped with a standard RS-232C-DB-9P connector at the
bottom (indent) and requires a standard RS-232C-DB-9S mating connector.
a) Make sure both, the cutter and the computer, are switched ‘OFF’. Connect one end of the serial
interface cable to the serial interface connector at the bottom (indent) of the cutting plotter.
b) Fasten the screws to ensure the connector.
c) Connect the other end of the serial cable to your computer.
Note :
· Using the serial communication, your cutter will not only be able to receive data
from the computer, but will also be able to send information to the computer (media
size,…).
· For proper operation of the serial communication, it will be necessary to match the
computer settings to the cutting plotter settings!
Cable wiring diagram :
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3.3 Connecting the power cable
a) Make sure the cutter’s power is switched ‘OFF’.
b) Plug the plotter-end of the power cable into the connector at the bottom (indent) of the plotter.
c) Plug the other end of the cable into an electrical outlet of the correct voltage and with a proper
grounding.
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3.4 Blade worn or broken
When the blade is worn or broken, you have to change it.
But you can reduce the failure. When you starts working with the cutting plotter, is it better to set the
pressure low and make a test cut. Then slowly increase the pressure when necessary.
Make a habit of it every time the cutting plotter has not worked for a few hours
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3.5 Cover Left : removal and installation.

Step 1 : Remove the 2 screws.
Step 2 : Push at the top back to remove the Left Cover.
Note :
To Reinstall the Left Cover perform above steps in reversed order.
3.6 Cover Right : removal and installation.

Step 1 : Remove the 2 screws.
Step 2 : Push at the top back to remove the Right Cover.
Note :
To Reinstall the Right Cover perform above steps in reversed order.
3.7 Y - rail : removal and installation.

Step 1 : Remove the Right Cover.
Step 2 : Remove the Left Cover.
Step 3 : Loosen the connectors of the Keyboard (JUNIOR PLUS).
a. Remove the Screw Plate (2 screws).

b. Pull out the connectors.
· Smallà rear right
· Largeà rear left
· Extra large (17 pins)à front
Step 4 : Slide the Y-rail to the right side.
Note :
To Reinstall the Y - rail perform above steps in reversed order.
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3.8 PCB Plate : removal and installation.

Step 1 : Loosen the 9 screws at the bottom of the PCB box. The two extremity screws at the back just a
few turns.
Step 2 : Remove the PCB Plate for a part.
Step 3 : Pull out the Motor and Encoder Cables.
Y-Motor : J8 Y-Encoder : J13

X-Motor : J9 X-Encoder : J14
Step 4 : Remove the PCB Plate.
Note :
To Reinstall the PCB Plate perform above steps in reversed order.
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3.9 X- motor : removal and installation.

Step 1 : Remove the Right Plate.
Step 3 : Remove the X-motor (2 screws).
Step 4 : Place the new X-motor in the hole of the Right Endplate. Tighten the X-motor with 2 screws,
but not to tight.
Step 5 : Place the belt around the pulley and adjust the tension of the belt. Then tighten the screws.
Tension = 3.5kg
Step 6 : Replace the PCB Plate.
Step 7 : Replace the Right Plate
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3.10 Y- motor : removal and installation.

Step 1 : Remove the Right Plate.
Step 3 : Remove the Y-motor (2 screws).
Step 4 : Place the new Y-motor on the Right Endplate. Tighten the Y-motor with 2 screws, but not to
tight.
Step 5 : Place the belt around the pulley and adjust the tension of the belt. Then tighten the screws.
Tension = 2.0kg
Step 6 : Replace the PCB Plate.
Step 7 : Replace the Right Plate.
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3.11 Steel belt : removal and installation.

Step 1 : Remove Cover Left.
Step 2 : Remove Cover Right.
Step 3 : Remove the Y-rail.
Step 4 : Remove the head cover.
Step 5 : Loosen the two Steel Belt Tension Screws (Screws at Y Drive Pulley side of the Junior Cutter).
Step 6 : Take of the Steel Belt from the Y Motor and Y Drive Pulley side.
Note :
To Reinstall the Steel Belt perform above steps in reversed order.
Caution :
Carry out the Steel Belt Tension Adjustment.
Steel Belt Tension Adjustment:
Step 1 : Set the Steel Belt in the middle of the Return Pulley and Motor Pulley
Step 2 : While moving the cursor left and right, turn the return pulley adjusting screws until the Steel Belt
does not tend to come off the pulley or move across the pulley.
Step 3 : When the belt adjustment is completed, use a belt tension jig to adjust the tension.
Move the cursor to the right position and measure the deflection of the belt at the center of the Y-rail.
Specification value : Between 95g and 100g
Step 4 : Finally, move the cursor left and right to check for belt skew.
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3.12 Mainboard
Checking the settings.
Before replacing the Mainboard, please check firmware connection between the JUNIOR (Plus/24) cutter
and the Junior (Plus) set-up program. In order for your cutter to be able to communicate with your host
computer, the communication settings on both machines have to match exactly. (ref. P 31)
Replace the Mainboard
Step 2 : Disconnect the connectors.
Step 3 : Loosen the 6 screws.
Step 4 : Remove the Mainboard.
Note :
To Reinstall the Mainboard perform above steps in reversed order.
Warning :
Check the DIP switch settings on the board.

The position of the DIP switches determines the type of machine where the board will be
used.
Junior 24 Þ DSW1 1-2-3 ON

4 OFF
Junior Plus Þ DSW1 1-3 ON

2-4 OFF
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3.13 Adjustment with the Cutting Plotter ‘ON’.

This section describes the adjustments of the machine, so the Cutting Plotter can work accurate.
For the adjustments of the Cutting Plotter, the power switch must be turned ‘ON’.
Caution :
When you want to restart the cutting plotter please make sure to wait until the power
‘ON’ LED goes out.
COM-port setting.
If the host computer is not able to communicate with the cutting plotter, check the COM-port settings in the
JUNIOR (Plus) set-up program.
· Open the SPECIAL drop down menu and select OPTIONS.
· Match the COM-port in the set-up program with the connected COM-port of the host computer (serial
cable connection cutting plotter / computer).
· Start up your cutting plotter again.
· Sometimes it is also necessary to restart your computer.
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3.14 How to correctly install new firmware?

Step 1 : Download the latest firmware from our website (www.mutoh.be) and install the new firmware into
a folder on your computer.
Step 2 : Switch ON the Junior Plus.
Step 3 : Start the Junior Plus Remote Software on your computer.
Note :
When you make connection, please wait until all parameters have been
loaded into your computer and until the Junior Plus has finished “bumping”
(at startup, the head moves to the left most position and returns to the right
side of the cutting plotter).
Step 4 : Go to “Firmware” and select “Upgrade”.
Note :
The user settings of the Junior Plus will be transferred to the computer (in
order to place them back after upgrade).
Step 5 : An Open Dialog Box will appear. Look for the Jrfx_xx.bin file. (x_xx refers to the number of the
new firmware)
Step 6 : The Remote Software will ask you to switch off the Junior Plus. Switch off the Junior Plus.
Step 7 : The Remote Software will ask you to switch on the Junior Plus. Switch on the Junior Plus.
Note :
A process bar will appear, showing you the status of the upgrade.
The process takes about 10 minutes.
The Junior Plus will make long beeps when it’s done and the Remote Software will show you if
the upgrade was successful. If this is not the case, repeat step 1 to step 7.
Important :
During the procedure, do not switch off the Junior Plus!
Step 8 : If the upgrade was successful, the Remote Software will ask you to restart the Junior Plus.
Caution :
When you want to restart the Junior Plus, please make sure to wait until the
power ‘ON’ LED goes out.
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Step 9 : The Remote Software will send back the parameters to the Junior Plus. The Junior Plus starts
bumping again, while saving the parameters to the Flash memory.
Note :
During saving of the parameters, a little knick in the movement of the head
could occur. Do not worry about that.
Step 10 : At the end of the upgrade the Remote Software will ask you to click the END button in the
Remote Software.
37 AP-74035, Rev 1.0 – 21 June 2001

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4.DIAGNOSTIC MODE
4.1 How to get in Diagnostic Mode?

· Go to ‘SPECIAL’.
· Select ‘OPTION’.
· Select ‘SERVICE’.
· Type the password “TubbyCut” and press ‘ENTER’.
Þ On the toolbar you get a new tool, namely ‘DIAGNOSTIC’.
4.2 Adjustment of the x and Y axis :

· First install media.
· Put a Pen in the Head.
· Go to ‘DIAGNOSTIC’.
· Select ‘MOTORS’.
· Select ‘ACCURACY’.
Þ Select ‘Robot 1’, that is the picture with “X-Y correct” on.
Þ Press on the picture. The Junior Plus Cutting Plotter will draw the picture ‘Robot 1’.
Þ Measure the X and Y-axis on the picture (The one in the middle.)
Þ Fill the fact in ‘Adjust X :’ and ‘Adjust Y :’and press ‘OK and SEND’.
· Select ‘ACCURACY’.
Þ Select ‘Robot 2’.

Þ Press on the picture. The Junior Plus Cutting Plotter will draw the picture ‘Robot 2’.
Þ Measure the X and Y-axis on the picture (The one in the middle.)
Þ Fill the fact in ‘Adjust X :’ and ‘Adjust Y :’and press ‘OK and SEND’. Make sure the facts are not
more then 200.30mm and not less then 199.70mm.
4.3 Control of the sensors.

· Select ‘SENSOR’.
· Press ‘START’ and move manual the media and head. On the computer you can see ‘covered’ or
‘uncovered’.
4.4 Check the Encoder.

· Select ‘ENCODER’.
· Move manual the Drive Rollers. You can see the values changing.
· Move manual the Cutting Head to the left and right. You can see the values changing.
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4.5 Check the Head movement.

· Select ‘AGING’.
· Press ‘START’ and the Head will repeat the asked movement.
Caution :
Make sure the Pressure rollers are down, so there will be no damage on the Head and
Pressure Rollers.
4.6 Check the keyboard

(Only for the Junior Plus)
· Select ‘KEYBOARD’.
· Here you can select “Check LED’s”, all LED’s should light up.
· You can also select “Check Key’s”. Press then the key on the keyboard and you should see pressed
key on your computer screen. Do not forget to stop this test.
4.7 Check the connector and battery in the Ram-card.

· Select ‘RM-CARD’.
· If there is no reaction after pressing start, the battery or connector is mal function.
40 AP-74035, Rev 1.0 – 21 June 2001

5.SOFTWARE : JUNIOR PLUS.
5.1 Installation of the software.
Your Junior Plus cutting plotter comes with 2 sets of software.
Setup Junior Series
The Junior setup software can be found on the CD-Rom as well as on the
floppy disk that comes with your Junior Plus cutting plotter.
Functions:
The setup software is needed to change your Junior Plus cutting plotter
settings and perform adjustments such as fine-tuning the offset.
Mutoh JuniorCut
Mutoh JuniorCut can be found on the CD-Rom that comes with your
cutting plotter.
Functions:
Bridge software to be used in combination with CorelDRAW™ (version 3.0
up to 9.0).
Uses CorelDRAW™ as master application for signcutting. File transport is
seamless via the application shortcut button.
Allows easy import of multiple file types, also including import filters of
several signcutting software.
Allows re-sizing, rotation, mirroring, cut-by-colour and many other
signcutting features.
· The CD-Rom contains the Setup Junior Series software Version 3.05. Please use the floppy disk to install
the Setup Junior Series software. This disk contains the latest version available at the time your plotter
was shipped. The latest version is also ready to be downloaded on the Internet on www.mutoh.be.
You can find it through ‘Download’ – ‘Drivers & Utilities for Mutoh Cutters’ – ‘Junior firmware update’ (‘.exe’
file)
· If you decide to install Mutoh JuniorCut from the CD-Rom at a later time, please note the installed set-up
software will be overwritten by the default Setup Junior Series software. You will need to re-install that
same software from the diskette or the Internet, after having installed Mutoh JuniorCut.
Install Mutoh JuniorCut only when you want to use the Mutoh in-the-box solution for sign making, in
combination with CorelDRAW™. Mutoh JuniorCut is not needed when you already possess another
professional cutting software. In that case, you can address the Junior Plus by selecting one of the
compatible Mutoh cutting plotter drivers from your cutting software. Compatible Mutoh plotter models are
SC-550, SC-650E, SC-650.
41 AP-74035, Rev 1.0 – 21 June 2001

5.1.1 How to install Mutoh JuniorCut?
If you choose to work with Mutoh’s in-the-box cutting solution JuniorCut, execute the next steps.
If you choose to use another cutting software, skip this part.
Load the Mutoh JuniorCut CD in the CD-Rom drive.

The setup sequence should start automatically. If, on
your computer, the installation does not start
automatically, open the CD via "Windows Explorer" or
via the "My Computer" icon on the desktop.
Select the user interface language
Select/create a destination directory for installation of

the program. This directory should also be used for the
installation of Setup Junior Series.
Proceed the setup sequence.
The installation is completed!
5.1.2 How to install Mutoh Setup Junior Series Software?
Please install this setup software from the diskette that was delivered in-the-box or from Mutoh Europe’s
Website on www.mutoh.be. Mutoh’s website contains the latest version of the setup software. You can find
it through ‘Download’ – ‘Drivers & Utilities for Mutoh Cutters’ – ‘Junior firmware update’ (‘.exe’ file)
Put the Junior Setup Software disk into the drive.

Start Windows explorer and start the installation
sequence by selecting the setup application icon.
When the program asks you for an installation
directory, choose the same directory as you used to
install the Mutoh JuniorCut software.
42 AP-74035, Rev 1.0 – 21 June 2001

5.1.3 Checking communication with the Junior Plus Cutting Plotter
Mutoh Setup Junior Series software has to be set-up in such a way that it can communicate with your Junior
Plus (bi-directional communication). This will also be the case for Mutoh JuniorCut.
To correctly configure the Setup Junior Series software, proceed as follows:
Make sure your JuniorPlus Cutter is switched ON.

Start ‘Setup Junior Series’
When communication is established the Setup Junior
Series window appears
Communication fails if a blue window appears on the

screen, indicating that the software is looking for your
Junior Cutter.
The blue window keeps on blinking when no
communication was found.
In this case, click CANCEL.
An error message will appear, indicating that no

communication was found.
Click OK
Mutoh Junior Setup software will pop up. This is the

default setting, meaning that the Version 1 window
appears.
All settings will be greyed out.
Perform the following menu sequence to change the

port settings :
Special
Options(Pull down)
Cutter connected to (Select COM port)
Click OK
43 AP-74035, Rev 1.0 – 21 June 2001

Make sure to select the correct COM-port.
Caution :
Some PCs use COM1 for the mouse and COM2 for other peripherals such as a modem
or a plotter.
Other PCs have an incorporated PS/2 port. In that case, select COM1 to connect the
Junior Plus.
Now close the Mutoh Junior Setup Software.

Restart it via the Start menu – Programs - JUNIOR –
JUNIOR
Keep on repeating the sequence above, until you have

found communication with your Junior Plus Cutter.
As soon as your Junior Plus Cutter is detected by the
software, all possible settings will be highlighted. And
the correct software window will appear.
When you switch ‘ON’ the Junior Cutter and you press ‘ONLINE’ and then start your Junior software, your
PC can give an error. (Program receives illegal command from cutter!!) It is so that your software could not
receive the settings of the Junior Cutter. You have to press the ‘receiving key’ on the software panel.
When you press ‘ONLINE’ on the Junior Cutter keyboard, the Setup Junior-series software will receive all the
settings of the Junior Cutter.
Before sending a file to the Cutter, the Head must be placed in his origin. The Cutter will start cutting
wherever it stands.
44 AP-74035, Rev 1.0 – 21 June 2001

5.2 Junior Plus setup program – control panel overview

Following is an overview of the JUNIOR Plus setup program control panel that discusses only the keys and
features which you need right away.
The installation of the JUNIOR Plus setup program is explained in the chapter above.
When starting the setup program the following will happen:

The program will try to communicate with the JUNIOR Plus cutting plotter. Make sure that the plotter’s
power switch is turned ON.
The NORMAL JUNIOR PLUS SETUP window will appear as shown below:
1.SPEED: Gives you the possibility to enter / alter the cutting speed.(max = 30 cm/s)
Factory default : 30 cm/s
The central LED on the cutting plotter is the entered SPEED. For manual fine
adjustment on the cutting plotter, see section SPEED CONTROL
ADJUSTMENT.
When using a signcutting program with MUTOH driver, the VS (speed)
command will override the entered speed value only when the VS/ZF is set to.
Speed LED indicates VS-velocity (speed) command value.
2.FORCE: Gives you the possibility to enter the tool force.(max. = 166 grams)
Factory default : 100 grams
The central LED on the cutting plotter is the entered FORCE. For manual fine
adjustment on the cutting plotter, see section FORCE CONTROL.
When using a signcutting program with MUTOH driver, the ZF (force) command
will override the entered force value only when the VS/ZF is set to ACCEPT.
Central LED indicates ZF-force command value.
45 AP-74035, Rev 1.0 – 21 June 2001

3.ORIGIN: Gives you the possibility to change the media origin point.
Factory default : X = 0 Y=0

Click the arrow keys to move the head to the new origin position. Confirm by
clicking on the SET key.
4.BLADE In order to get MUTOH quality from your JUNIOR Plus cutter, it is advisable to
ADJUSTMENT: perform a blade offset adjustment.
Factory default : 0.5 mm
For details refer to section: OFFSET ADJUSTMENT PROCEDURE in the

Junior Plus User’s Guide.
5.RECEIVING from / Click one of these keys to send or receive all the settings to or from the JUNIOR
SENDING to KEY: Plus cutting plotter. (this is not needed for all the settings).
6.Open and send file / Click on ‘Open and send file’ key to select and send a file to the JUNIOR cutting
Send last file KEY : plotter. As a result of clicking on the ‘Send last file’ key, your last selected file
will be send to the JUNIOR cutting plotter.
7.ADVANCED / Gives you the possibility to select the normal or advanced JUNIOR PLUS
NORMAL KEY: SETUP window.
46 AP-74035, Rev 1.0 – 21 June 2001

When pressing the ADVANCED KEY, the following window will appear :
8.COMMUNICATION: Gives you the possibility to set the communication settings of the JUNIOR
Plus cutting plotter to match the settings of the host computer & cutting
software.
Factory default :
Baudrate : 9600
Databits : 8
Parity : none
Stopbits : 1
Protocol : Xon / Xoff
9.TOOLKIND: Gives you the possibility to select the tool you want to use, namely Knife
or Pen.
Factory default : Drag Knife
10.SHUFFLE LENGTH: Gives you the possibility to set the media length which will be transported
through the cutting plotter during the shuffle sequence. (max. = 5000mm)
Factory default : 1200 mm
11.PAGE MODE: Gives you the possibility to access the media pre-feed cycle function.
Factory default : Mode1
47 AP-74035, Rev 1.0 – 21 June 2001

12.PROGRAM STEP: Gives you the possibility to set the value of the program step. (0.025 &
0.01 mm)
Factory default : 0.025
13.VS / ZF: Give you the possibility to enable or disable the VS (velocity / speed) &
ZF (tool force) command value sent to the cutting plotter.
Factory default : ACCEPT
14.OFFSET: Displays the current knife offset.

Factory default: 0.6
15.ORIGIN: Gives you the possibility to select a preset origin. (Center or Lower Right)
Factory default : Lower right
16.SMOOTHING: Gives you the possibility to switch smoothing on or off.

Factory default : ON
17.SMOOTHING WINDOW: Gives you the possibility to determine the size of the smoothing window.
Factory default: 4 vectors
0 vectors àbetter quality but slower

20 vectors àless quality but faster
48 AP-74035, Rev 1.0 – 21 June 2001

5.3 Junior (24) setup program – control panel overview

Following is an overview of the JUNIOR setup program control panel that discusses only the keys and
features which you need right away.
The installation of the JUNIOR setup program is explained in the chapter above.
When starting the setup program the following will happen:
The program will try to communicate with the JUNIOR cutting plotter. Make sure that the plotter’s power
switch is turned ON.
The NORMAL JUNIOR SETUP window will appear as shown below:
1.SPEED: Gives you the possibility to enter / alter the cutting speed.
Factory default : 200 mm/s
The vertical position of the speed control knob on the cutting plotter
corresponds with the entered SPEED. For manual fine adjustment on the
cutting plotter, see section SPEED CONTROL ADJUSTMENT.
A professional signcutting program uses a special command (VSn; ) to control
the cutting speed from within the software.
If you want to control the cutting speed from within your cutting plotter software,
make sure the VS/ZF setting is set to ACCEPT.
If you want to control the cutting speed via the Junior setup software, make sure
the VS/ZF setting is set to IGNORE.
Vertical position of the speed control knob = Speed set via VS (velocity) –
Command.
2.FORCE: Gives you the possibility to enter the tool force.

Factory default : 100 grams
The vertical position of the force control knob on the cutting plotter is the
entered FORCE. For manual fine adjustment on the cutting plotter, see section
FORCE CONTROL KNOB ADJUSTMENT.
A professional signcutting program uses a special command (ZFn;) to control
the cutting force from within the software.
If you want to control the cutting force from within your cutting plotter software,
make sure the VS/ZF setting is set to ACCEPT.
If you want to control the cutting force via the Junior setup software, make sure
the VS/ZF setting is set to IGNORE.
Vertical position of the force control knob = ZF-force command value.
49 AP-74035, Rev 1.0 – 21 June 2001

3.ORIGIN: Gives you the possibility to change the media origin point.
Factory default : X = 0 Y=0
Click the arrow keys to move the head to the new origin position. Confirm by
clicking on the SET key.
4.BLADE In order to get MUTOH quality from your JUNIOR cutter, it is advisable to
ADJUSTMENT: perform a blade offset adjustment.
Factory default : 0.5 mm
For details refer to section: OFFSET ADJUSTMENT PROCEDURE refer to
the Junior Plus User’s Guide.
5.RECEIVING from / Click one of these keys to send or receive all the settings to or from the JUNIOR
SENDING to KEY: cutting plotter.
6.ADVANCED / Gives you the possibility to select the normal or advanced JUNIOR SETUP
NORMAL KEY: window.
50 AP-74035, Rev 1.0 – 21 June 2001

When pressing the ADVANCED KEY, the following window will appear:
7.COMMUNICATION: Gives you the possibility to set the communication settings of the JUNIOR
cutting plotter to match the settings of the host computer & cutting
software.
Factory default :
Baudrate : 9600
Databits : 8
Parity : : none
Stopbits : 1
Protocol : Xon / Xoff
8.TOOLKIND: Gives you the possibility to select the tool you want to use, namely Drag
Knife or pen.
Factory default : Drag Knife
9.SHUFFLE LENGTH: Gives you the possibility to set the media length which will be transported
through the cutting plotter during the media loading sequence.
Factory default : 1000 mm
51 AP-74035, Rev 1.0 – 21 June 2001

10.PAGE MODE: Gives you the possibility to access the media pre-feed cycle function.
Factory default : PG0
Cutting plotter software normally uses a special command at the end of a
job, to set a new origin position. The same command also is sometimes
used to (inter) connect long plots and make sure that there is no gap, nor
an overlap.
This special command is the PAGE command (Pgxxx;) and the Page
Mode determines how your cutter reacts to it. Different Page Modes exist
in order to be compatible with every type of cutting software.
The Page Mode parameter gives access to three possible page modes.
The Page Mode determines the cutter’s reaction to a PAGE command
sent by the cutting software. The PAGE command is a command which
is used to relocate the origin after a job is finished.
A page-command looks like this: “PG;” or “Pgn;” with “n” a number in
millimetres.
If the PAGE command “PG;” is sent, the cutter will automatically perform
a pre-feed cycle and relocate the origin.
If the PAGE command “Pgn;” is sent, the number mentioned after the
PG command will be interpreted differently, depending on the page mode
you have chosen :
Page Mode 0 : A new piece of media will be pre-fed and the new origin
will be located approximately 1 cm (0.4”) beyond the furthest vector.
Page Mode 1 : The new origin is located “n” millimetres beyond the
last vector that was sent.
Page Mode 2 : The new origin is located “n” millimetres beyond the
previous origin position.
A : Original origin.
B : End point last vector
C : New origin with Page Mode 1
D : New origin with Page Mode 2
11.PROGRAM STEP: Gives you the possibility to set the value of the program step. (0.025 &
0.01 mm)
Factory default : 0.025
The program step determines the smallest possible movement of the
tool head.
It can be set either to 0.025 mm (40 steps per mm) or 0.010 mm (100
steps per mm).
In case you notice that your outputs are 2.5 times too large or 2.5 times
too small, please change this setting.
12.VS / ZF: Give you the possibility to enable or disable the VS (velocity / speed) &
ZF (tool force) command value sent to the cutting plotter.
Factory default : ACCEPT
VS / ZF Commands are used in professional sign cutting software to
control SPEED and cutting FORCE from within the software.
13.ORIGIN: Gives you the possibility to select a preset origin.

Factory default : 0,0
52 AP-74035, Rev 1.0 – 21 June 2001

5.4 Using the Software.

Explanation for CorelDRAWÔ…
To Mutoh JuniorCut…
To Setup Junior Series…
To Junior Plus Cutting Plotter
When executing following 4 steps, you can make your first sign.
Step 1: Import the selected items from CorelDRAWÔ to Mutoh JuniorCut

After you have created an image, select the objects to
be cut click the ‘Application Launch’ button.
Mutoh JuniorCut is automatically opened.

The selected items are being imported to Mutoh
JuniorCut.
Import file from other software into Mutoh JuniorCut.
Go to ‘File’.
Select ‘Import’.
Select the file to be imported.
Press ‘Import’.
Step 2: Select all objects.
Go to ‘Edit’.
Choose ‘Select All’.
53 AP-74035, Rev 1.0 – 21 June 2001

Step 3: Rotate your selection before giving the cutting command.
This can/has to be done if you want your output

orientation to match your screen orientation!
Go to ‘Edit’ and choose ‘Select All’.

Go with the pointer to the middle of the selected items.
Click your right mouse key.
Select ‘rotate’ and fill in … (270 or 90 degrees).
Press ‘Apply’ and close the window.
Step 4: Cutting out selected items.
Go to ‘cut’.
Select ‘plot’.
When all parameters are correct, confirm with ‘OK’.

Click ‘OK’ in upper window.
The Junior Plus Cutting Plotter is activated.
54 AP-74035, Rev 1.0 – 21 June 2001

Following items are a selection of the wide range of possibilities of the in the-box software.
Change Settings for Junior Plus Cutting Plotter
· When you are in JuniorCut, go to ‘Cut’.

· Select ‘MUTOH Control’.
· Setup Junior Series is being opened.

· You can now alter settings.
· Press ‘Advanced’ to alter advanced

settings.
· When settings are changed, push the ‘send
to plotter’ button.
· Don’t forget to close the Setup Junior Series
window before you go back to JuniorCut. If
forgotten, an error will occur. This error can
be overcome by simply closing the Setup
Junior Series window.
Appoint colour-tickets to objects

· Select object(s).
· Go to the coloured squares at the bottom.
· Click on the desired colour.
Cut by colour
· Make sure the right colour of vinyl is loaded!
· Go to ‘Cut’.
· Select ‘Plot’.
· Go to the ‘Options’ menu.
· Tick the ‘Cut by colour’ box.
· Confirm with ‘OK’.
· Cut complete colour layer? Click on ‘Cut’.
· The colour you’ve chosen is now being cut.
55 AP-74035, Rev 1.0 – 21 June 2001

Cut by colour – a second colour

· Make sure the right vinyl (second colour) is loaded.
· Select the items to be cut in the second colour.
· Follow the steps as above.
· The second colour will now be cut.
Hide or show border
· Go to ‘View’.
· Select or unselect ‘Show Sign Blank’.
Hide or show filling
· Go to ‘View’.
· Select or unselect ‘Fill’.
Search on Help
· Go to ‘Help’.
· Select ‘Contents’.
· Select ‘Contents’.
· Search for what you’re looking for.
56 AP-74035, Rev 1.0 – 21 June 2001

6.EXPLODED VIEW JUNIOR PLUS
57 AP-74035, Rev 1.0 – 21 June 2001

Final Assy (MY-2400-11000)

58 AP-74035, Rev 1.0 – 21 June 2001
X-Y Assy (MY-2400-10000)
59 AP-74035, Rev 1.0 – 21 June 2001

PCB Plate (MY-25250)
60 AP-74035, Rev 1.0 – 21 June 2001

X-rail Assy (MY-24000X)
61 AP-74035, Rev 1.0 – 21 June 2001

X-rail Assy LC (MY-2400-10400)
62 AP-74035, Rev 1.0 – 21 June 2001

Y Assy LC (MY-24000Y)
63 AP-74035, Rev 1.0 – 21 June 2001

Penhead Assy (MY-25864)
64 AP-74035, Rev 1.0 – 21 June 2001

Y Drive Belt (MY-20324)
65 AP-74035, Rev 1.0 – 21 June 2001

Pressure Roller Assy LC (MY-21193)
66 AP-74035, Rev 1.0 – 21 June 2001

Ninja Wheels (MY-33234)
67 AP-74035, Rev 1.0 – 21 June 2001

X-motor Assy LC (EY-10004)

68 AP-74035, Rev 1.0 – 21 June 2001
Y-Drive Pulley (MY-25057)
69 AP-74035, Rev 1.0 – 21 June 2001

Return Pulley (MY-25075)
70 AP-74035, Rev 1.0 – 21 June 2001

Y-motor Assy LC (EY-10014)
71 AP-74035, Rev 1.0 – 21 June 2001

72 AP-74035, Rev 1.0 – 21 June 2001

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MAINTENANCE MANUAL

JUNIOR PLUS CUTTING PLOTTER

COPYRIGHT ã 2001 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-74035, Rev 1.0 – 21 June 2001

5 AP-74035, Rev 1.0 – 21 June 2001

6 AP-74035, Rev 1.0 – 21 June 2001

1.2 Junior Plus.

· Axial Speed from 450 to 848 mm/s.

1.3 Junior 24.

7 AP-74035, Rev 1.0 – 21 June 2001

1.4 Working Conditions

§ Temperature : 5°C to 40°C (41°F to 104°F)

§ Temperature : Room temperature 16°C to 32°C (61°F to 90°F)

§ Temperature : 2°C per hour

§ Temperature : 0°C to 50°C (32°F to 122°F)

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

8 AP-74035, Rev 1.0 – 21 June 2001

1.5.1 What’s in the box?

Contents of the Junior Plus plotter box :

A. JUNIOR Plus cutting plotter unit.

B. MUTOH Junior Plus Cutter User’s Guide.

C. One knife holder with pre-mounted cutting blade.

E. Set of 2 water-based fibre-tip pens.

F. Spare cutting mat.

H. RS-232 interface cable.

I. RS-232 adapter cable (DB 9 / DB 25).

J. Set of 2 conveyor rollers.

K. Set of 2 guiding profiles for the conveyor rolls.

9 AP-74035, Rev 1.0 – 21 June 2001

A. JUNIOR cutting plotter unit.

B. Junior User’s Guide.

C. One knife holder with pre-mounted cutting blade.

D. Set of 2 spare cutting blades and 1 spring.

E. Set of 2 water-based fibre-tip pens.

F. Spare cutting mat.

H. RS-232 interface cable.

I. RS-232 adapter cable (DB 9 / DB 25).

J. Set of 2 conveyor rollers.

K. Set of 2 guiding profiles for the conveyor rolls.

A cutting plotter stand for the Junior 24 cutter is available as an option.

10 AP-74035, Rev 1.0 – 21 June 2001

1.5.2 Getting to know the cutter parts.

11 AP-74035, Rev 1.0 – 21 June 2001

12 AP-74035, Rev 1.0 – 21 June 2001

2. Power switch Switches the cutting plotter ‘ON’ or ‘OFF’.

13 AP-74035, Rev 1.0 – 21 June 2001

14 AP-74035, Rev 1.0 – 21 June 2001

15 AP-74035, Rev 1.0 – 21 June 2001

2. Power switch Switches the cutting plotter ON or OFF.

16 AP-74035, Rev 1.0 – 21 June 2001

1.5.3 Control Panel JUNIOR PLUS

1. SPEED CONTROL BUTTON

Ø Draft = selected speed X 2

Ø Normal = selected speed

Ø Quality = selected speed / 2

2. FORCE CONTROL BUTTON

Ø Leftmost LED = selected force –80%

Ø Central LED = selected force

Ø Rightmost LED = selected force +80%

17 AP-74035, Rev 1.0 – 21 June 2001

3. POWER ON/OFF LED à green