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Alignments? Post some pictures.

While the USB port is not officially supported, it should not cause your issue.

It the overheat is caused by the head, then the head needs replacing.

When they are selected in the RIP, any RIP settings should override the printer panel settings. You can look at the RIP to see what is selected. But you are correct, the PF is typically NOT sent from the RIP.

Is your head height set to low?

typically your nozzle check will print the channels on the carriage opposite of what they are on the carriage. I.e. if the carriage is KCMY left to right K will print firts, then C then M them Y So your nozzle check will look like YMCK left to right.

Overheat is a head error, typically bad head.

Great news!

We print all our banners at G2, B2 or B4 depending on viewing distance. Never printed a banner at 1440 with the texture of a banner, you can only really get benefit from 1440 on photopaper. Print flawlessly at G2, 720x720 8 pass bi directional. It is possible that you have head alignment...

What does your nozzle check look like? Have you done a PF adjust?

http://en.wikipedia.org/wiki/Magnuson%E2%80%93Moss_Warranty_Act Enacted in 1975, it is the federal statute that governs warranties on consumer products. A "consumer" is a buyer of consumer goods for personal use.

Does it give an error or just say warming or locks up? Which version firmware?

Means that there is a fuse blown for head #4. There is 1 fuse for each channel, head 4 has 2 channels.

Does it print internal patterns? Nozzle check, palette?

http://www.mutoh.com/mutoh_dealers.php

There are a LOT of parts on a Falcon Outdoor 62" printer. Sounds like you either have not replaced the proper part(s) or maybe not replaced them properly. More information would be more helpful to point you in the right direction. A good picture of your nozzle check might help as well.

Do a couple of cleanings from the front panel, should clear right up.

Yes the margin measures from the black strip on the printer to the contrast 'white' of the media.

Typically a power error. Can sometimes be remedied by cycling power.

While I have not seen these, previous versions were VERY informative and useful.