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Replacement Procedure of Ink Tower Unit Old-New
Replacement Procedure of Ink Tower Unit Old-New
[1] FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)
Notes
• Check remaining ink in the ink cartridges for all the
colors (500 ml or more).
• To block a tube, nip the tube with a forceps by the
base (close to the fulcrum) of the forceps.
Accessory
• Drain the inks for all the colors.
(Drain ink completely or the ink will leak during
B. 060-50111
replacement.)
XF_BODY_PCB2 (1 pc)
• Plug the tubes over the ports until the gap between
the tube and the port base is 1 mm or less.
• After attaching each tube, check for no buckling.
(Observe the directions of the existing tubes and
clips before replacing.)
• Do not attach back the removed ink cartridges until
indicated to do so.
QQ Tools and Miscellaneous
• Do not switch ON the interlock switch of the front
cover until indicated to do so. (1) Forceps (at least 9)
• Note that the FW, for which the procedure instructs (2) Phillips screwdriver
the replacement of the Ink Tower Unit, has both (Size No. 2, 100 to 250 mm long)
KCMY and KCRY models. Use the instructions (3) Slotted screwdriver
corresponding to the printer on which you are (4) Nipper
working.
(5) Steel measure (150 mm long)
(6) Permanent marker
(for marking tubes)
(7) USB flash drive (including the latest firmware)
923--00
Issued by Overseas Technical Department, RISO KAGAKU CORPORATION
CONFIDENTIAL
[2] FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)
1. Removing Covers and Opening the (8) Open the engine PCB unit and the power supply
Tower unit.
(Round tip IT3C M3X8; 4 pcs each)
(1) In test mode, lower the BP unit to the lower limit
position.
• BP ELEVATOR MOTOR TO DOWN: TM093020
(2) In test mode, move the ink pan unit to the On-Belt Engine PCB unit
position.
• INK PAN ON-BELT POSITION: TM093028
(3) Using a thin metal ruler, manually unlock and
open the front door of the printer and switch OFF
the interlock switch.
Power supply unit
* Do not close the front door nor switch ON the
front door interlock switch until indicated to do
so.
(4) Remove all the ink cartridges from the printer.
* Do not close the front door nor switch ON the (9) Open the ink tower unit.
front door interlock switch until indicated to do (Round tip IT3C M3X8; 2 pcs)
so.
(5) Turn OFF the printer power.
(6) Remove the rear cover.
(Round tip IT3C M3X10; 7 pcs)
Ink tower unit
Rear cover
[3] FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)
(11) Remove the face down paper receiving tray. (4) Unplug the drain tubes of the pressurized ink
tanks for all the colors from the sealing ports on
the ink overflow pan and insert the tube ends into
the ink overflow pan to drain the ink by the next
step.
* Be careful not to allow ink to drip from the
tubes.
Forceps
CONFIDENTIAL
[4] FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)
(7) Open the ink supply solenoid valves for all the (10) Unplug the FPCs (flat cables) around the head
colors sequentially in test mode (for 10 times tube from the connectors on the HDR PCB to
for each color) to allow the inks to drop through clear them so that you can access the head tubes
the ink supply tubes to the negative pressure ink of head No.6 for all the colors in the HH (Head
tanks. Holder) unit.
* Confirm that all ink cartridges are removed.
• K INK-SUPPLY VALVE OPEN: TM093051
• C INK-SUPPLY VALVE OPEN: TM093052
• M (R) INK-SUPPLY VALVE OPEN: TM093053
• Y INK-SUPPLY VALVE OPEN: TM093054
(8) Drive the ink circulation pumps for all the colors
sequentially in test mode (up to 30 secs. for each
color) to pass the inks in the negative pressure
ink tanks to the pressurized ink tanks, and then
to drain them from the drain tubes into the ink
overflow pan.
• CIRCULATION PUMP MOTOR K: TM092031
• CIRCULATION PUMP MOTOR C: TM092032
• CIRCULATION PUMP MOTOR M (R): TM092033 Before clearing away the FPCs
FPCs
[5] FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)
(11) Unplug from print head No.6 the "Ink Inlet" head (14) Drive the ink circulation pumps for all the colors
tubes for all colors and allow the inks in the ink sequentially in test mode (up to 30 secs. for each
bus to drop completely in the negative pressure color) to transfer the inks in the negative pressure
ink tanks (for approx. 30 secs. for each color). ink tanks to the pressurized ink tanks, and to drain
Then, connect the head tubes to the original ports them from the drain tubes into the ink overflow
on the No.6 print heads. pan.
* Be careful not to allow ink to drip from the • CIRCULATION PUMP MOTOR K: TM092031
tubes. • CIRCULATION PUMP MOTOR C: TM092032
* Detach or attach the head tubes only at head • CIRCULATION PUMP MOTOR M (R): TM092033
No.6.
• CIRCULATION PUMP MOTOR Y: TM092034
(15) Connect back the drain tubes of the pressurized
K, M (R) ink tanks for all the colors to the sealing ports on
Ink outlet the pressurized ink tanks.
Ink inlet C, Y Sealing port
Ink inlet
Ink outlet
Head tube
(Inlet/Outlet)
(16) If the ink overflow pan has some ink, drain it.
[6] FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)
3. Unplugging Wires (4) Unplug all the connectors on the main unit relay
(1) Turn OFF the printer power. PCB (19 or 21 pcs).
(2) Open the wire saddle (1 pc) for the tower wiring.
Connector
[7] FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)
(2) Cover the waste ink tube port of the ink tower with
(4) Cover the cut end tips of the tubes (the ink supply
the cap supplied in the Ink Tower shipment.
tubes) coming down from the ink cartridges with
the caps supplied in the Ink tower shipment.
Cap
(5) Open the three wire saddles that secure the ink
(3) Mark and cut the ink supply tubes connected to tubes running to and from the ink bus.
the negative pressure ink tanks for all the colors.
* Be careful not to allow ink to drip from the
tubes.
* Cut the tubes at about 40 mm from the top
surface of the negative pressure ink tanks.
Y M (R) C K
CONFIDENTIAL
[8] FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)
(6) Unplug all the "Ink-in" and "Ink-out" tubes from the 5. Removing the Ink Tower
Ink Bus for all colors and plug all the unplugged (1) Lift the ink tower and remove it from the printer by
tube tips with caps, and do the same with the tube unhooking it from the two mounting hooks on the
ports on the Ink Bus. The details on the caps to printer.
use are given on below in red colored text.
* Be careful not to catch wires and tubes
* Be careful not to allow ink to drip from the surrounding the tower when removing the tower.
tubes.
* The caps to use on the tips of the ink tubes If the main unit relay PCB was replaced in step 3-(3),
pulled off from the Ink Bus are those caps which follow steps (2) to (5).
are on the brand-new replacement Ink Tower (2) Remove the mounting screws on the main
ink tubes corresponding to these just unplugged unit relay PCB from which the connectors are
from the Ink Bus. (8 pcs) removed in step 3-(4).
* To plug the Ink Bus ports, use the caps from (Bind M3X8; 4 pcs)
the Elbow Joints which are mounted on the (3) Pinch the tip of the hook on the spacers (2 pcs) to
Negative pressure ink tanks on the new release the main unit relay PCB and remove the
replacement Ink Tower and also those additional PCB.
caps included in the replacement Ink Tower
shipment. (8 pcs)
(7) Pull out from the printer all these "Ink-in" and "Ink-
out" tubes (total 8), through the two rectangular
ink tube passage holes (through-holes) on the
printer rear metal frame shown on the next
picture.
M (R), Y K, C
CONFIDENTIAL
[9] FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)
6. Mounting the replacement Ink Tower "Through-holes for the ink tubes on the printer
Hook part A (new ink tower) firmly on the two mounting rear frame"
hooks on the printer. M (R), Y K, C
7. Connecting Tubes
"Ink-out" tube connecting port
(1) Bring up and pass the "Ink-out" ink tubes (the ink
tubes between the Ink Buses and the Negative
Pressure Ink Tanks) through the two rectangular
ink tube through-holes on the printer rear metal
plate, towards the Ink Bus ports.
Remove the rubber caps placed on the "Ink-out" Ink bus
ports on the Ink Buses in the previous step 4-(6).
Insert the Ink Tube clips included in the Ink Tower
shipment, one each through the tip of the ink (2) Bring up and pass the “Ink-in” ink tubes (the ink
tubes to clamp the tubes onto the Ink Bus "Ink- tubes between the Pressurized Ink Tanks and
out" ports (lower ports) after plugging the hoses the Ink Buses) through the two rectangular ink
onto the ports. tube through-holes on the printer rear metal plate,
towards the Ink Bus ports.
* Check the ink-color-marked-bands on the tubes
Remove the rubber caps placed on the “Ink-in”
to connect the tubes on the correct ports.
ports on the Ink Buses in the previous step 4-(6).
* Be careful not to tangle or buckle the ink tubes Insert the Ink Tube clips included in the Ink Tower
for all the colors.
shipment, one each through the tip of the ink
"Color K marked band for the Ink-out tube as tubes to clamp the tubes onto the Ink Bus “Ink-in”
an example." ports (upper ports) after plugging the hoses onto
the ports.
* Check the ink-color-marked-bands on the tubes
to connect the tubes on the correct ports.
* Be careful not to tangle or buckle the ink tubes
This end of the ink tube plugs on the ink bus "Ink-Out" for all the colors.
port.
"Color K marked band for the Ink-in tube as an
example."
This end of the ink tube plugs on the ink bus "Ink-In"
port.
CONFIDENTIAL
[10] FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)
"Through-holes for the ink tubes on the printer (4) Remove the caps from the end-tip of the ink
rear frame" supply tubes of which were attached in step 4-(4).
M (R), Y K, C
Then, attach the clips (which are included in the
Ink tower shipment) over all four ink supply tubes
and connect the tubes onto the elbow joints on
the Negative pressure ink tanks, and secure the
tubes on the elbow joints with the clips.
* Be careful not to allow ink to drip from the
tubes.
* Confirm the color identification mark bands on
"The order in connecting the ink tubes" the tubes to connect correct ink tubes onto the
1. "Ink-in" tube for color K Negative pressure ink tanks.
2. "Ink-in" tube for color C
* The orientation of the clips (which way the grip
3. "Ink-in" tube for color M (R) of the clips face) can be ignored.
4. "Ink-in" tube for color Y
"Ink-in" tube connecting port
Ink bus
Elbow joint
M (R), Y K, C
CONFIDENTIAL
[11] FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)
8. Connecting Wires (3) Secure the tower wires with the wire saddle (1
pc).
If the main unit relay PCB was replaced in step 3-(3),
follow step (1). If the PCB was not replaced, follow (1)'.
(1) Connect all the connectors removed in step 3-(4)
(19 or 21 pcs) to the main unit relay PCB.
Connector
CONFIDENTIAL
[12] FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)