CONFIDENTIAL

[1] FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)

FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)

This replacement procedure explains how to replace Preparation
the ComColor FW with the old type, pressurized/
negative pressure tank assembly (with trochoid pump),
QQ Parts for Use
with the new type, pressurized/negative pressure tank A. 060-75537
assembly II (with cylinder pump). Ink tower unit II; SU (1 pc)

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

(10) Remove the top left side cover.

 (Round tip IT3C M3X10; 2 pcs)

(7) Remove the rear left side cover.

(It is not necessary to remove the right side cover)
 (Round tip IT3C M3X10; 3 pcs)

Top left side cover

Rear left side

2 cover

[3]
(11) Remove the face down paper receiving tray.
Face down paper receiving tray
(12) Remove the head holder cover.
 (Round tip IT3C M3X8; 4 pcs)
Head holder cover
2. Draining Ink
* Images in this section show replacement of color M.
(1) Check that the front door is open, turn ON the
printer power, and enter test mode.
When the following errors appear in test mode,
cancel the display.
• Z002-2125 / • Z002-2126
• Z002-2127 / • Z002-2128
• Z022-1255 / • W051-1301
(2) Disable ink temperature adjustment in test mode.
• INK TEMPERATURE ADJUST ON/OFF: TM096025
(Change the setting from 0 to 1.)
(3) Block the drain tubes of the pressurized ink tanks
for all the colors with forceps.
Forceps
CONFIDENTIAL
FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)
(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.
(5) After reading the following three cautions, remove
the forceps blocking the drain tubes and drain
the ink in the pressurized ink tanks into the ink
overflow pan.
* Check that the ink is draining.
* If the tube is bent, straighten it.
* Allow one color ink to drain completely from
the drain tube and then remove the forceps
blocking the next color.
(i.e. - allow the ink to drain one by one.)
(6) Drive the ink circulation pumps for all the colors
sequentially in test mode (up to 30 secs. for
each color) to transfer the inks in the negative
pressure ink tanks into the pressurized ink tanks
and 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
• CIRCULATION PUMP MOTOR Y: TM092034
 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

• CIRCULATION PUMP MOTOR Y: TM092034

(9) Turn OFF the printer power.

FPCs

After clearing away the FPCs

FPCs (flat cables)

 CONFIDENTIAL

[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.

(12) Connect the FPCs to the original connectors.

(13) Confirming that the printer front door is open, turn
ON the printer power, and enter into test mode.
When the following errors appear in test mode,
cancel the error displays by pressing the "Close"
button on each error display.
• Z002-2125 / • Z002-2126
• Z002-2127 / • Z002-2128
• Z022-1255 / • W051-1301
 CONFIDENTIAL

[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.

Unplug all the connectors

(19 or 21 pcs).

(4)' Unplug the connectors on the main unit relay

PCB (6 pcs).

(3) Check the parts number of the main unit relay

PCB inside the ink tower unit.
* Replace the main unit relay PCB if the unit has
parts number "060-50054" printed in the second
picture below.

Unplug the connector (6 pcs)

(5) Viewing the ink tower from the pressurized

Main unit relay
PCB ink tank side (as shown on the picture below),
disconnect the connector on the right (1 pc).

Connector

If the main unit relay PCB was replaced, follow step

(4).
If the PCB was not replaced, follow (4)'.
 CONFIDENTIAL

[7] FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)

4. Disconnecting the Tubes "Top View of Pressurized/

Negative Pressure Tank Assembly"
(1) Block the waste ink tube of the ink tower with Pressurized Ink Tank
forceps and unplug the waste ink tube from the
ink overflow pan. The tube clip will be reused later
when connecting the waste ink tube on the newly
replaced ink tower.
* Be careful not to allow ink to drip from the tube.
Forceps
Ink supply tube
port

Negative Pressure Ink Tank

(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

[8]
(6) Unplug all the "Ink-in" and "Ink-out" tubes from the
Ink Bus for all colors and plug all the unplugged
tube tips with caps, and do the same with the tube
ports on the Ink Bus. The details on the caps to
use are given on below in red colored text.
* Be careful not to allow ink to drip from the
tubes.
* The caps to use on the tips of the ink tubes
pulled off from the Ink Bus are those caps which
are on the brand-new replacement Ink Tower
ink tubes corresponding to these just unplugged
from the Ink Bus. (8 pcs)
* To plug the Ink Bus ports, use the caps from
the Elbow Joints which are mounted on the
Negative pressure ink tanks on the new
replacement Ink Tower and also those additional
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
FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)
5. Removing the Ink Tower
(1) Lift the ink tower and remove it from the printer by
unhooking it from the two mounting hooks on the
printer.
* Be careful not to catch wires and tubes
surrounding the tower when removing the tower.
If the main unit relay PCB was replaced in step 3-(3),
follow steps (2) to (5).
(2) Remove the mounting screws on the main
unit relay PCB from which the connectors are
removed in step 3-(4).
 (Bind M3X8; 4 pcs)
(3) Pinch the tip of the hook on the spacers (2 pcs) to
release the main unit relay PCB and remove the
PCB.
Mounting screws on the main unit relay PCB
Spacers
(4) Fit part B (main unit relay PCB for replacement)
over the spacer hooks to attach.
(5) Tighten the mounting screws on the main unit
relay PCB.
 (Bind M3X8; 4 pcs)

[9]
6. Mounting the replacement Ink Tower
Hook part A (new ink tower) firmly on the two mounting
hooks on the printer.
The two mounting hook
locations on the printer.
7. Connecting Tubes
(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"
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
tubes to clamp the tubes onto the Ink Bus "Ink-
out" ports (lower 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
for all the colors.
"Color K marked band for the Ink-out tube as
an example."
This end of the ink tube plugs on the ink bus "Ink-Out"
port.
CONFIDENTIAL
FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)
"Through-holes for the ink tubes on the printer
rear frame"
M (R), Y K, C
"The order in connecting the ink tubes"
1. "Ink-out" tube for color K
2. "Ink-out" tube for color C
3. "Ink-out" tube for color M (R)
4. "Ink-out" tube for color Y
"Ink-out" tube connecting port
Ink bus
(2) Bring up and pass the “Ink-in” ink tubes (the ink
tubes between the Pressurized Ink Tanks and
the Ink Buses) 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-in”
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
tubes to clamp the tubes onto the Ink Bus “Ink-in”
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
for all the colors.
"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

"Ink-in & Ink-out tubes connected"

Elbow joint

(5) Remove the forceps from the Waste ink tube of

(3) Secure the "Ink-out" tubes and "Ink-in" tubes with
the wire saddles on the printer rear frame at the
ink tube through-hole locations.
the Ink tower, which was clamped on the tube in
previous step 4-(1). Then connect the tube on the
waste ink drain port of the Ink tower, with the clip
slid over the tube, and secure the tube firmly on
the port with the clip.

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.

9. Upgrading the Firmware

(1) Plug a USB flash drive with the latest firmware
Connect all the connectors
(19 or 21 pcs) into the USB port on the side of the operation
panel and turn ON the power after confirming the
(1)' Connect the connectors removed in step 3-(4)' front cover is open.
(6 pcs) to the main unit relay PCB. Operation panel

Plug the connectors (6 pcs)

(2) Connect the connector removed in step 3-(5)

(2) When the following screen appears on the
(1 pc).
operation panel, press the Stop key and download
all by overwriting. After pressing the Stop key, pull
out the USB flash drive.

Connector
 CONFIDENTIAL

[12] FW Series - Replacement Procedure of Ink Tower Unit (Old → New Type)

(3) After the firmware is upgraded, enter test mode.

When the following errors appear in test mode,
cancel the display.
• Z002-2125 / • Z002-2126
• Z002-2127 / • Z002-2128
• Z022-1255 / • W051-1301

10. Filling Ink

(1) Switch the printer into head replacement
mode from test mode.
• HEAD REPLACE MODE: TM096017
(Change the setting from 0 to 1.)
(2) Turn OFF the power.
(3) Attach all the ink cartridges.
(4) Close the Front door of the printer to activate
the interlock switch ON.
(5) Turn ON the power and wait until the initial ink
supply is completed (for approx. 7 min.).

11. Initial Ink Supply

(1) Perform the initial ink supply and wait until it
completes
(for approx. seven min.).
• INK INITIAL FILLING: TM093011
(2) Repeat step (1) for 15 times.

12. Attaching Covers and Closing the

Tower
(1) In the reverse order of steps in section 1, close
the ink tower unit, the engine PCB unit, and the
power supply unit and attach removed covers.