Technical Information Bulletin

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1 Mutoh America Inc South 47th Street, Suite 102 Phoenix, Arizona USA Tel. (480) Fax (480) Technical Information Bulletin FROM: MUTOH AMERICA - Service & Support. Re Release date:august 1, 2006 MAI Bulletin # Falcon Outdoor Eco-Ultra Conversion Dear Mutoh customer, This Technical Information Bulletin explains how to convert an installed Falcon Outdoor Junior or Falcon Outdoor 48 /62 printer from Eco-Solvent Plus ink to Mutoh s new Eco-Ultra ink. This Technical Information Bulletin is divided into the following sections: Tools necessary for conversion:... 2 Conversion Process Replacing maintenance station waste tubing... 2 Falcon Outdoor Junior requires removing covers as well as removal of the maintenance station. This Process has changed since 7/31/06. Falcon Outdoor 48" and 62" require only removing right cover. 2. Installing the new wiper... 4 Falcon Outdoor Junior wiper is replaced while maintenance station is removed for tubing. Falcon Outdoor 48" and 62" removing covers to access wiper may only be required. 3. Replacing Eco-Plus ink with Eco-Ultra ink... 5 Important Installed Falcon Outdoor Junior and Falcon Outdoor 48 /62 printers need an Eco-Ultra ink modification kit installed before loading Eco-Ultra ink, Ultra ready printers will have an Ultra ink label affixed to the printer. Loading Eco-Ultra ink without performing the necessary hardware modifications will result in damage to the ink delivery system (i.e. waste tube clogging and resulting leakage) which may lead to permanent printer damage. FO Ultra Conversion Process TIB Page1 of 5

2 TOOLS REQUIRED FOR CONVERSION To convert a Falcon Outdoor Junior or Falcon Outdoor 48 /62 printer, be sure you have the recommended Eco-Ultra Conversion Kit. Printer Falcon Outdoor Junior & Falcon Outdoor 48 /62 Parts Wiper 1 each Waste tubing instruction sheet Order number Junior / CONVERSION INSTRUCTIONS Converting a Falcon Outdoor Junior or a Falcon outdoor 48 /62 requires three steps: 1. Replacing the waste tubing 2. Installing a new wiper 3. Replacing the ink set 1. Replace the Waste Tubing on the Maintenance Assembly Step 1: Remove the Right hand cover, All models Step 2: Remove the panel cover, Falcon Outdoor Junior only Step 3: Remove the front cover, Falcon Outdoor Junior Step 4: Remove the Y rail (top) cover, Falcon Outdoor Junior Step 2: Panel cover Step 4: Top Y rail cover Step 1: Right hand cover Step 3: Front cover FO Ultra Conversion Process TIB Page 2 of 5

Falcon Outdoor 48" and 62"; replacing the waste tubing only requires removing the right end cover.

Locate the connection joint at the point just where that tubing enters the body of the printer.

Falcon Outdoor Junior; replacing the waste tubing requires removing the maintenance station from the printer to access the connection joint.

Step 5: Remove the panel mounting cover by lowering the electronics box (3 screws) Falcon outdoor Junior: Remove 2 screws from underneath and

3 Falcon Outdoor 48" and 62"; replacing the waste tubing only requires removing the right end cover. Go to step 12 and find the tubing that is looped through the metal bracket. Locate the connection joint at the point just where that tubing enters the body of the printer. Replace the milky colored tubing with the clear tubing included in the kit. Replace the right end cover. Falcon Outdoor Junior; replacing the waste tubing requires removing the maintenance station from the printer to access the connection joint. Follow the next steps to replace the waste tubing on the Junior. Step 5: Remove the panel mounting cover by lowering the electronics box (3 screws) Falcon outdoor Junior: Remove 2 screws from underneath and lower the heater control panel to rest on the electronics box. Remove 2 screws from the control panel bracket and lean it forward. It is best to remove the cable so that it does not fall off of the printer during the next steps. The maintenance station can now be accessed. During reassembly press the collar of the connector down on two sides to make sure it is secure. FO Ultra Conversion Process TIB Page 3 of 5

Step 6: Removing the maintenance station: Step 7: Step 8: Step 9: Disconnect the waste tubes on the back side of the maintenance station assembly Using the tubes removed in step 7, measure and cut 2

See Section 2 below. Step 10: Step 11: Step 12: Insert waste tubes through the right side of the frame. Reinstall the maintenance station assembly.

4 Step 6: Removing the maintenance station: Step 7: Step 8: Step 9: Disconnect the waste tubes on the back side of the maintenance station assembly Using the tubes removed in step 7, measure and cut 2 pieces of tube supplied in the kit Install the new tubes to the back side of the maintenance assembly. Replace the 'wiper' at this point while you have the maintenance statiion accessible. See Section 2 below. Step 10: Step 11: Step 12: Insert waste tubes through the right side of the frame. Reinstall the maintenance station assembly. Before tightening the screws, push the maintenance station assembly all the way back and let it sit in position Tighten screws. Connect the waste tubes from the maintenance station assembly to the waste tubing from the waste bottle. Be sure the tubing forms a loop in the bracket prior to entering the waste bottle. 2. Install New Wiper Step 1: Slide the head carriage to the left side Step 2: Remove the original wiper (a paper clip with a hook formed on one end may be useful to help remove the old wiper) Step 3: Before inserting the new wiper, moisten the wiper with isopropyl alcohol FO Ultra Conversion Process TIB Page 4 of 5

Step 4: Insert the moistened wiper with a pair of tweezers or using latex gloves NOTE Do not touch wiper with your bare hand to prevent body oils from coming in contact with the wiper rubber and

5 Step 4: Insert the moistened wiper with a pair of tweezers or using latex gloves NOTE Do not touch wiper with your bare hand to prevent body oils from coming in contact with the wiper rubber and nozzle plate. Use latex gloves or tweezers. Clean wiper with isopropyl alcohol in case of contact. Replace Eco-Plus ink with Eco-Ultra Ink After the hardware modification is complete, Eco-Plus ink can be flushed out and new Eco-Ultra loaded. Step 1: Step 2: Use up your Eco-Plus ink supply or as much as possible Flush Eco-Plus ink from the system 1. Press the Menu button until Utility is displayed, Press ENTER 2. Press the Menu button again until Wash is displayed, Press ENTER 3. Empty the waste bottle while the power is ON 4. Answer the display questions confirming twice that you have emptied the waste. Press either value button (bottom center 2 buttons) to answer YES, Twice 5. Follow the prompts on the display, which will ask you to remove the ink cartridges 6. The printer will begin pumping out excess ink from the lines. Confirm that waste liquid is moving from both waste tubes through to the waste bottle 7. When prompted for cleaning jig (wash cart) insert all cartridges for 48 or 62 printers NOTE: insert appropriate cleaning cartridge Black or color for the 38 (Junior) printer 8. When the cleaning liquid has passed completely, the display will prompt you to remove the cleaning cartridges. Remove them and let the printer again pump without cartridges 9. When the dry pumping is complete (two complete times for 38 ) the printer should report: KCMY56 or KCMY Discharged 10. Insert the new ink cartridge set and the printer will begin inking up the printer 11. Once the INK FILL is complete the printer will report Ready to Plot on the display 12. Print a check nozzle pattern: Press and hold the Shift (upper right button) and then press ENTER. If all colors are present in the check nozzle pattern then the conversion is complete. If one or more colors are missing then perform two Powerful cleanings back to back without waiting between them a. Press Menu button until Utility is displayed. Press ENTER b. Press Menu button again until Clean is displayed, Press Value to change to Powerful c. Press ENTER to confirm the choice of a Powerful cleaning d. When complete repeat steps a and b one more time e. Print the check nozzle pattern again to confirm. Repeat step 10 after 30 minutes if colors are missing Ready to Print with Eco-Ultra Ink NOTE: Be sure to use Eco-Ultra profiles profiles can be found on Onyx and Scanvec-Amiable web sites, or if using Mutoh Diamond Shield media on Mutoh s website. FO Ultra Conversion Process TIB Page 5 of 5

User Maintenance Kit

User Maintenance Kit Dear Customer, This document will guide you through the maintenance for the Océ CS9000 Eco-Solvent series printers. All necessary tools, accessories and parts are collected in one