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Replacement Procedure of Pressurized Negative Pressure Tanks Old-New
Replacement Procedure of Pressurized Negative Pressure Tanks Old-New
• Attach tubes until the gap with the port base is 1 mm (7) USB flash drive (including the latest firmware)
or less.
• Remove or attach the tank assemblies one by one. 1. Removing Covers and Opening the
• When attaching a new tank assembly, check the Tower
position in relation to the tank assemblies already
(1) In test mode, move the BP unit to the lower limit
attached.
position.
(Do not install assemblies slanted or the ink will
leak.) • BP ELEVATOR MOTOR TO DOWN: TM093020
• After attaching every tube, check for no buckling. (2) In test mode, move the ink pan unit to the
(Observe the directions of attached tubes and clips extended position.
before replacing.) • INK PAN ON-BELT POSITION: TM093028
• Do not attach ink cartridges until indicated to do so. (3) Unlock the front cover lock, open the front cover,
• Do not turn ON the interlock in the front cover until and turn OFF the interlock.
indicated to do so. * Do not turn ON the interlock until indicated to do
• Note that the FW, for which these procedures instruct so.
how to replace pressurized/negative pressure (4) Remove all the ink cartridges.
tanks, has both KCMY and KCRY models. Use the * Do not attach ink cartridges until indicated to do
instructions corresponding to the printer on which so.
you are working.
923-00006-002
Issued by Overseas Technical Department, RISO KAGAKU CORPORATION
CONFIDENTIAL
(5) Turn OFF the power. (9) Open the ink tower unit.
(6) Remove the rear cover. (Round tip IT3C M3X8; 2 pcs)
(Round tip IT3C M3X10; 7 pcs)
Rear cover
Ink tower unit
(8) Open the engine PCB unit and the power supply
unit.
(Round tip IT3C M3X8; 4 pcs each)
2. Draining Ink (5) Remove the forceps blocking the drain tube and
drain the ink in the pressurized ink tank into the
* Images in this section show replacement of color M.
ink overflow pan.
(1) Check that the front cover is open, turn ON the
power, and enter test mode. * Check that the ink is draining.
When the following errors appear in test mode, * If the tube is bent, straighten it.
cancel the display. * Allow one color ink to drain completely from
• W051-1301 / • Z002-2125 the drain tube and then remove the forceps
• Z002-2126 / • Z002-2127 blocking the next color.
(i.e. - allow the ink to drain one by one)
• Z002-2128 / • Z022-1255
(6) Drive the ink circulation pumps for all the colors
(2) Disable ink temperature adjustment in test mode.
sequentially in test mode (up to 30 secs. for each
• INK TEMPERATURE ADJUST ON/OFF: TM096025 color), pass the inks in the negative pressure ink
(Change the setting from 0 to 1.) tanks to the pressurized ink tanks, and then drain
(3) Block the drain tubes of the pressurized ink tanks them to the ink overflow pan.
for all the colors with forceps. • CIRCULATION PUMP MOTOR K: TM092031
• CIRCULATION PUMP MOTOR C: TM092032
• CIRCULATION PUMP MOTOR M (R): TM092033
• CIRCULATION PUMP MOTOR Y: TM092034
Forceps (7) Open the ink fuse solenoid valves for all the
colors sequentially in test mode (for 10 times
for each color) to allow the inks to drop in the
(4) Pull out the drain tubes of the pressurized ink replenishment tubes to the negative pressure ink
tanks for all the colors from the sealing ports on tanks.
the ink overflow pan and connect the tube ends to * Check that the ink cartridge has been removed.
the ink overflow pan. • K INK-SUPPLY VALVE OPEN: TM093051
* Be careful not to allow ink to drip from the • C INK-SUPPLY VALVE OPEN: TM093052
tubes.
• M (R) INK-SUPPLY VALVE OPEN: TM093053
• Y INK-SUPPLY VALVE OPEN: TM093054
K C M (R) Y
CONFIDENTIAL
(8) Drive the ink circulation pumps for all the colors (11) Unplug the head tubes of head 6 for all the colors
sequentially in test mode (up to 30 secs. for each at the head sides (ink inlets) and allow the inks in
color), pass the inks in the negative pressure ink the ink baths to drop completely in the negative
tanks to the pressurized ink tanks, and then drain pressure ink tanks (for approx. 30 secs. for each
them to the ink overflow pan. color). Then, connect the head tubes to the
• CIRCULATION PUMP MOTOR K: TM092031 original ports.
• CIRCULATION PUMP MOTOR C: TM092032 * Be careful not to allow ink to drip from the
tubes.
• CIRCULATION PUMP MOTOR M (R): TM092033
• CIRCULATION PUMP MOTOR Y: TM092034 * Detach or attach the head tubes only at head 6.
Head tube
(Inlet/Outlet)
FPCs
CONFIDENTIAL
(14) Drive the ink circulation pumps for all the colors 3. Unplugging Wires
sequentially in test mode (up to 30 secs. for each (1) Turn OFF the power.
color), pass the inks in the negative pressure ink
(2) Unplug all the wire connectors on the ink sensors
tanks to the pressurized ink tanks, and then drain
for the negative pressure ink tanks and unhook
them to the ink overflow pan.
the wires from the hooks.
• CIRCULATION PUMP MOTOR K: TM092031
Unplug the connector
• CIRCULATION PUMP MOTOR C: TM092032
• CIRCULATION PUMP MOTOR M (R): TM092033
• CIRCULATION PUMP MOTOR Y: TM092034
(15) Connect the drain tubes of the pressurized ink
tanks for all the colors to the sealing ports on the
pressurized ink tanks.
Sealing port
(16) If the ink overflow pan has some ink, drain it.
Y M (R) C K
CONFIDENTIAL
"Top View of Pressurized/ (7) Pull out the ink tubes for all the colors from the
Negative Pressure Tank Assembly"
joints.
Pressurized side
* Be careful not to allow ink to drip from the
tubes.
Joint
Replenishment
tube port
(8) Put the cap on the joint port at which the tube was
pulled out.
Negative pressure side * Remove the cap from part A (arrowed in the
figure shown below) to use the cap.
(6) Put a cap on the cut tube end to the ink cartridge.
* Remove the cap from part A (arrowed in the Cap
figure shown below) to use the cap.
Cap
Part A
Part A (9) Pull out the pressurized air tubes for all the colors
on the common air chamber.
(5)' Pull out the replenishment tube connected to the
negative pressure ink tank from the elbow joint.
Elbow joint
K C M (R) Y
CONFIDENTIAL
* Remove and attach the tank assemblies one by (3) Remove the O-ring retained on the ink tower or
one in steps 5 and 6 below. the tank assembly and put part H (new O-ring) on
part A (new tank assembly).
* Put part H in completely.
5. Removing Tank Assemblies
* When part H is wet with ink, it is easier to place.
* Images in this section show replacement of color M.
(1) Remove the ink pump cover plate.
(Round tip IT3C M3X8; 2 pcs) 6. Attaching Tank Assemblies
Ink pump cover plate * Images in this section show replacement of color M.
(1) Pass part G through part C (black clip) when
replacing color Y or pass part F through part C
when replacing a color other than color Y, connect
part G or F to port a on part A, and secure it with
the attached clip.
O-ring
Tube height
Part F < Part G
Part F Part G
Tank assembly
(2) Pass part D (pressurized air tube, 300 mm) (4) Attach part A on the ink tower.
through part B (silver clip), connect it to port b on
part A, and secure it with the clip.
Port b
Arrow view
(3) Pass part E (negative pressure air tube, 135 mm) * Aim part A so that the centers of the fastening
through part B (silver clip), connect it to port c on holes on it coincide with the screw holes
part A, and secure it with the clip. respectively and attach part A straight.
Arrow view
Port c
Part A
Part A
(5) Fix part A to the ink tower with the screws. (2) Put out the cap from the tube end, pass the tube
(Small pan-head screw, through part C (black clip), connect the tube
double-washer M3X8; 4 pcs) connected to port a with the joint, and secure the
tube with the clip.
* Be careful not to allow ink to drip from the
tubes.
Part A
(3) Remove the cap from the tube end, pass the tube
through part C (black clip), and connect the elbow
joint at the tube end that is connected to the tank
7. Connecting Tubes assembly to the replenishment tube.
(1) Pass part D (pressurized air tube, 300 mm) that * Be careful not to allow ink to drip from the
has been attached in step 6-(2) through part B tubes.
(silver clip), connect it to the pressurized common * You do not need to care about the orientation of
air chamber, and secure it with the clip. the clip.
* Spares of part C (black clip) are supplied.
(16 pcs).
K Part D C M (R) Y
CONFIDENTIAL
"When steps (2) and (3) have been performed 8. Attaching the Ink Circulation Pump
for all the colors"
PCB
(1) Reattach the ink circulation pump PCB (removed
from part A in step 4-(2).
* Always replace the ink circulation pump PCB
accompanying the pump.
(2) Attach part K (edge saddle) to part J (ink pump
PCB bracket; 3C) and secure the pump wires for
each color with the edge saddle.
"Part K attached to Part J"
K C M (R) Y
Part E
* Check that the ink circulation pump PCBs are
"When tubes are connected completely" placed from the left in the order of colors K, C,
M (R), and Y.
Negative pressure Pressurized ink
ink tank side tank side * To secure the wires for color M (R) and Y, use
the same edge saddle.
Part J
Edge saddle
(Part K)
K C M(R), Y
Part A
CONFIDENTIAL
(3) Temporarily fasten the screw on the left side of (6) Install the ink circulation pump PCBs with part M
part J. (bind M3X6).
(Round tip IT3C M3X8; 1 pc) * Check that the PCBs are placed from the left in
the order of colors K, C, M (R), and Y.
(Bind M3X6; 8 pcs)
9. Wiring Wires
(1) Use part I (reusable band) to remove any slack of
the pump wires for color Y near the connector and
secure them.
* Spares of part I (reusable band) are supplied
(3 pcs).
Part L
Abut
(2) Check the parts number of the main unit relay (5) Remove the hooks for the spacers (2 pcs) and
PCB inside the ink tower unit. detach the main unit relay PCB.
* Replace the main unit relay PCB if the unit has
parts number "060-50054" printed in the second
picture below.
If the main unit relay PCB is not replaced, skip steps (3)
to (8) but follow (3)'.
(3) Unplug all the connectors on the main unit relay
PCB (19 or 21 pcs).
(9) Remove the ink path actuator wires. 3. Unplug the air pump connector.
(Leave the connector connected to the ink path Air pump
actuator.)
1. Remove the pressurized common air chamber
and let it hang down in the front.
(Round tip IT3C M3X8; 2 pcs)
Pressurized common air chamber
Let it hang down in the front 5. Open the edge saddle, pull the connector for
the pressure open air valve outside the tower
2. Unplug the connectors for the pressure control
frame metal plate, and unplug the connector.
valve and the air flow rate control valve.
Pressure open air valve Tower frame metal plate
Pressure control Air flow rate control
valve valve
6. Unplug the connectors for the negative 3. Connect the three connectors of part O that
pressure control valve and the negative remain after following step 9-(10)-1 to the
pressure open air valve. ink circulation pump PCB for colors K, C, M
(R) and secure them with the reusable band
(3 pcs).
Negative pressure
open air valve
6. Pass the wires upward further, connect the Pressure open air valve
connector for the air pump, and secure them
with the reusable band around the area (3
pcs).
Air pump Tower frame
metal plate
10. Connect the connectors for the pressure (12) Connect the wire connectors to the ink sensors for
control valve and the air flow rate control the negative pressure ink tanks for all the colors
valve. and hook the wires with the hooks.
Pressure control valve Air flow rate control valve Plug the connector
(13) Block the drain tubes for all the colors of the new
tank assemblies (part A) with forceps.
Forceps
(14) Pull out the drain tubes for all the colors of the
new ink tank assemblies (part A) from the sealing
Plug the connectors (3 pcs)
ports for the pressurized ink tanks and insert the
(11) Attach the pressurized common air chamber tube ends into the ink overflow pan.
removed in step 9-(9)-1. * Be careful not to allow ink to drip from the
(Round tip IT3C M3X8; 2 pcs) tubes.
* Do not pinch wires.
Pressurized common air chamber
CONFIDENTIAL
(15) Connect the wire connectors to all the colors of (2) When the following screen appears on the
the ink sensors for the pressurized ink tanks and operation panel, press the Stop key and download
hook the wires with the hooks. all by overwriting. After pressing the Stop key, pull
out the USB flash drive.
Plug the connector
Forceps
CONFIDENTIAL
(2) Drive the ink circulation pumps for all the colors 13. Attaching Covers and Closing the
sequentially in test mode and stop the pump once Tower
no colorless ink comes out from the ends of the
(1) Fold the downstream tubes for the external filter
drain tubes.
circulation tanks on all the colors of the replaced,
• CIRCULATION PUMP MOTOR K: TM092031 new tank assemblies and fix with the wire bands.
• CIRCULATION PUMP MOTOR C: TM092032 After fixing it, set it in the space between the
• CIRCULATION PUMP MOTOR M (R): TM092033 tanks as shown in the figure below.
• CIRCULATION PUMP MOTOR Y: TM092034 * Spares of the wire band are supplied (8 pcs).
(3) Insert the drain tubes for all the colors into the
sealing ports on the ink overflow pan and tuck the
tubes in the slits folding them in Z.
* Connect from the left, K, C, M (R), and then Y
sequentially.
* Be careful not to allow ink to drip from the
tubes.
F G H I Supplementals
H. SOL_ORING_K (1 pc)
B. T_CLIP_5 (4 pcs)
I. Reusable band; RST-130V0 (1 pc)
300 mm
CONFIDENTIAL
J. 060-68159 O. 060-53097
Ink pump PCB bracket; 3C (1 pc) Ink path actuator wires SK (1 pc)
K. 665-02075
WES-0507; Paper ejection wing edge saddle
(3 pcs)
L. 060-75531
Ink pump PCB bracket 1C; SU (1 pc)
N. 060-50111
XF-BODY-PCB2 (1 pc)