CONFIDENTIAL

FW Series - Replacement Procedure of Pressurized/

[1] Negative Pressure Tanks (Old → Old Type)

FW Series - Replacement Procedure of Pressurized/

Negative Pressure Tanks (Old → Old Type)
Notes Preparation
• Check remaining ink in the ink cartridge for the color QQ Supplied Parts
to be replaced (500 ml or more). See the Supplied Parts List (on p. 14).
• To block a tube, nip it with forceps by the base.
• Drain the ink only for the color to be replaced. QQ Tools and Miscellaneous
(Drain ink completely or the ink will leak during
(1) Forceps (at least 1)
replacement.)
(2) Phillips screwdriver
• Attach tubes until the gap with the port base is 1 mm
(Size No. 2, 100 to 250 mm long)
or less.
(3) Slotted screwdriver
• When replacing two or more color tank assemblies,
remove or attach the tank assemblies one by one. (4) Nipper
• When attaching a new tank assembly, check the (5) Steel measure (150 mm long)
position in relation to the tank assemblies already (6) Permanent marker
attached. (for marking tubes)
(Do not install assemblies slanted or the ink will
leak.)
1. Removing Covers and Opening the
• After attaching every tube, check for no buckling.
(Observe the directions of attached tubes and clips Tower
before replacing.) (1) In test mode, move the BP unit to the lower limit
• Do not attach ink cartridges until indicated to do so. position.

• Do not turn ON the interlock in the front cover until
indicated to do so.
• Note that the FW, for which these procedures instruct
how to replace pressurized/negative pressure
tanks, has both KCMY and KCRY models. Use the
instructions corresponding to the printer on which
you are working.
• BP ELEVATOR MOTOR TO DOWN: TM093020
(2) In test mode, move the ink pan unit to the
extended position.
• INK PAN ON-BELT POSITION: TM093028
(3) Unlock the front cover lock, open the front cover,
and turn OFF the interlock.
* Do not turn ON the interlock until indicated to do
so.
(4) Remove all the ink cartridges.
* Do not attach ink cartridges until indicated to do
so.
(5) Turn OFF the power.

060-75493-108
Issued by Overseas Technical Department, RISO KAGAKU CORPORATION
 CONFIDENTIAL

FW Series - Replacement Procedure of Pressurized/

[2] Negative Pressure Tanks (Old → Old Type)

(6) Remove the rear cover. (9) Open the ink tower unit.
 (Round tip IT3C M3X10; 7 pcs)  (Round tip IT3C M3X8; 2 pcs)

Rear cover

Ink tower unit

(10) Remove the top left side cover.

(7) Remove the rear left side cover.  (Round tip IT3C M3X10; 2 pcs)
(It is not necessary to remove the right side cover)
 (Round tip IT3C M3X10; 3 pcs)

Rear left side

cover Top left side cover

(11) Remove the face down paper receiving tray.

(8) Open the engine PCB unit and the power supply
unit.
 (Round tip IT3C M3X8; 4 pcs each)

Face down paper receiving tray

Engine PCB unit
(12) Remove the head holder cover.
 (Round tip IT3C M3X8; 4 pcs)

Power supply unit

Head holder cover


[3]
2. Draining Ink
* Images in this section show replacement of color M.
(1) Check that the front cover is open, turn ON the
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.
• Disable ink temperature adjustment: TM096025 (6) Drive the ink circulation pump for the color to
(Change the setting from 0 to 1.)
(3) Block the drain tube of the pressurized ink tank to
be replaced with forceps.
Forceps
(4) Pull out the drain tube of the pressurized ink tank
to be replaced from the sealing port on the ink
overflow pan and attach the tube end to the ink
overflow pan.
* Be careful not to allow the ink to drip from the
tube.
CONFIDENTIAL
FW Series - Replacement Procedure of Pressurized/
Negative Pressure Tanks (Old → Old Type)
(5) Remove the forceps blocking the drain tube and
drain the ink in the pressurized ink tank into the
ink overflow pan.
* Check that the ink is draining.
* If the tube is bent, straighten it.
* When replacing two or more color tanks, 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).
be replaced in test mode (up to 30 secs.), pass
the ink in the negative pressure ink tank to the
pressurized ink tank, and then drain it to 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
(7) Open the ink fuse solenoid valve for the color to
be replaced in test mode (for 10 times) to allow
the ink to drop in the replenishment tube to the
negative pressure ink tank.
* Check that the ink cartridge has been 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
 CONFIDENTIAL

FW Series - Replacement Procedure of Pressurized/

[4] Negative Pressure Tanks (Old → Old Type)

(8) Drive the ink circulation pump for the color to
be replaced in test mode (up to 30 secs.) to
pass the ink in the negative pressure ink tank to
the pressurized ink tank and drain it to 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
(9) Turn OFF the power.
(10) Unplug the FPCs around the head tube from the
connectors on the HDR PCB to clear them so that
you can access the head tube of head 6 for the
color to be replaced in the HH unit.
(11) Unplug the head tube of head 6 for the color to
be replaced at the head side (ink inlet) and allow
the ink in the ink bath to drop completely in the
negative pressure ink tank (for approx. 30 secs.).
Then, attach the head tube to the original port.
* Be careful not to allow the ink to drip from the
tube.
* Detach or attach the head tube only at head 6.
K, M (R)
Ink outlet
Ink inlet C, Y
Ink inlet
Ink outlet

Head tube
(Inlet/Outlet)

Before clearing away the FPCs

FPCs

After clearing away the FPCs

FPCs
 CONFIDENTIAL

FW Series - Replacement Procedure of Pressurized/

[5] Negative Pressure Tanks (Old → Old Type)

(12) Connect the FPCs to the original connectors. (16) If the ink overflow pan has some ink, drain it.
(13) Check that the front cover is open, turn ON the
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
(14) Drive the ink circulation pump for the color to
be replaced in test mode (up to 30 secs.) to
pass the ink in the negative pressure ink tank to
the pressurized ink tank and drain it to the ink
overflow pan. 3. Unplugging Wires
• CIRCULATION PUMP MOTOR K: TM092031 * Images in this section show replacement of color M.
• CIRCULATION PUMP MOTOR C: TM092032 (1) Turn OFF the power.
• CIRCULATION PUMP MOTOR M (R): TM092033 (2) Unplug all the wire connectors on the ink sensors
• CIRCULATION PUMP MOTOR Y: TM092034 for the negative pressure ink tanks and unhook
the wires from the hooks.
(15) Connect the drain tube of the pressurized ink
tank to be replaced to the sealing port on the Unplug the connector
pressurized ink tank.
Sealing port

Unhook from the hook

(3) Unplug the wire connector on the ink sensor

for the pressurized ink tank to be replaced and
unhook the wires from the hook.
Unplug the connector

Unhook from the hook

 CONFIDENTIAL

FW Series - Replacement Procedure of Pressurized/

[6] Negative Pressure Tanks (Old → Old Type)

(4) Unplug the wire connector on the ink circulation

pump to be replaced and unhook the wires from
the hook.
(Leave the connector connected with the yellow
wires.)
Unhook from the hook

When replacing tank assemblies again that have been

replaced before, follow steps (3)' and (4)' instead of (3)
and (4).
(3) Mark and cut the replenishment tube connected
to the negative pressure ink tank to be replaced.
Unplug the connector
* Be careful not to allow the ink to drip from the
tube.
Connected to the tank * Cut the tube about 40 mm from the top surface
assembly
of the negative pressure ink tank.
Connector

Connected to the wires

(yellow wires)

4. Pulling out Tubes

* Images in this section show replacement of color M.
(1) Pull out the negative pressure air tube for the Y M (R) C K
color to be replaced on the common air chamber.
"Top View of Pressurized/
Negative Pressure Tank Assembly"
Pressurized side

Replenishment
tube port

(2) Tilt part A (new tank assembly) from side to side

and up and down so that the colorless ink is filled
evenly.
* Try to make as few bubbles as possible.
* Be careful not to disperse the colorless ink. Negative pressure side
 CONFIDENTIAL

FW Series - Replacement Procedure of Pressurized/

[7] Negative Pressure Tanks (Old → Old Type)

(4) Put a cap on the cut tube end to the ink cartridge.
* Remove the cap from part A (arrowed in the
figure shown below) to use the cap.
Cap
(6) Put the cap on the joint port at which the tube was
pulled out.
* Remove the cap from part A (arrowed in the
figure below) to use the cap.

Cap

Part A

Part A
(3)' Pull out the replenishment tube connected to the
negative pressure ink tank to be replaced from
(7) Pull out the pressurized air tube for the color to be
the elbow joint.
replaced on the common air chamber.

Elbow joint

(4)' Put a cap on the end of the pulled-out tube to the

ink cartridge (See 4-(4).)
(5) Pull out the tube for the color to be replaced from
the joint.
* Be careful not to allow the ink to drip from the
tube.

Joint K C M (R) Y
 CONFIDENTIAL

FW Series - Replacement Procedure of Pressurized/

[8] Negative Pressure Tanks (Old → Old Type)

* When replacing two or more color tank assemblies,
remove and attach the tank assemblies one by one
in steps 5 and 6 below.
5. Removing Tank Assemblies
* Images in this section show replacement of color M.
(1) Remove the ink pump cover plate.
 (Round tip IT3C M3X8; 2 pcs)
Ink pump cover plate
(3) Remove the O-ring retained on the ink tower or
the tank assembly and put part H (new O-ring) on
part A (new tank assembly).
* Put part H in completely.
* When part H is wet with ink, it is easier to place.
6. Attaching Tank Assemblies
* 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.

Port a
(2) Remove the tank assembly for the color to be
replaced.
* Pressing down the ink overflow pan, pull out the
tank assembly to remove it.
 (Small pan-head screw, Part A
 double-washer M3X8; 4 pcs)
O-ring Tube height
Part F < Part G

Part F Part G

Tank assembly

Tank assembly removed

 CONFIDENTIAL

FW Series - Replacement Procedure of Pressurized/

[9] Negative Pressure Tanks (Old → Old Type)

(2) Pass part D (pressurized air tube, 300 mm) * Aim part A so that the centers of the fastening
through part B (silver clip), connect it to port b on holes on it coincide with the screw holes
part A, and secure it with the clip. respectively and attach part A straight.

Port b
Arrow view

Part A

(3) Pass part E (negative pressure air tube, 135 mm) * After attaching part A to the ink tower, release
through part B (silver clip), connect it to port c on part A and check that it is placed correctly.
part A, and secure it with the clip. "Checks before tightening screws"

Port c

1) Top surface level of the

negative pressure ink
tank
2) Front surface level of
Part A the negative pressure
ink tank
Part A
(4) Attach part A on the ink tower.
• Check that 1) and 2) of the replaced tank
Part H assembly(ies) is/are level with tank assemblies
that were not replaced.
• If not level, attach again.

(5) Fix part A to the ink tower with the supplied

screws.
 (Small pan-head screw, double-washer
Arrow  M3X8; 4 pcs)
view

Part A

Part A
 CONFIDENTIAL

FW Series - Replacement Procedure of Pressurized/

[10] Negative Pressure Tanks (Old → Old Type)

(6) Attach the ink pump cover plate.

 (Round tip IT3C M3X8; 2 pcs)
Ink pump cover plate

(3) Remove the cap from the tube end, pass the tube
7. Connecting Tubes
(1) Pass part D (pressurized air tube, 300 mm) that
has been attached in step 6-(2) through part B
(silver clip), connect it to the pressurized common
air chamber, and secure it with the clip.
through part C (black clip), connect the elbow joint
at the tube end, which is connected to the tank
assembly, to the replenishment tube, and secure
the tube with the clip.
* Be careful not to allow the ink to drip from the
tube.
* You do not need to care about the orientation of
the clip.
* Spares of part C (black clip) are supplied.
(4 pcs).

"When steps (2) and (3) have been performed"

K Part D C M (R) Y

(2) Put out the cap from the tube end, pass the tube
through part C (black clip), connect the tube
connected to port a with the joint, and secure the
tube with the clip.
* Be careful not to allow the ink to drip from the
tube.
 CONFIDENTIAL

FW Series - Replacement Procedure of Pressurized/

[11] Negative Pressure Tanks (Old → Old Type)

(4) Pass part E (negative pressure air tube, 135 mm) 8. Connecting Wires
that has been attached in step 6-(3) through part (1) Connect the wire connectors to the ink sensors
B (silver clip), connect it to the negative pressure for the negative pressure ink tanks and hook the
common air chamber, and secure it with the clip. wires with the hooks.
Plug the connector

Hook the wires

Part E
(2) Block the drain tube for the replaced, new tank
"When tubes are connected" assembly (part A) with forceps.
Negative pressure Pressurized ink
ink tank side tank side

Forceps

(3) Pull out the drain tube of the replaced, new ink
Part A
tank assembly (part A) from the sealing port for
the pressurized ink tank and attach the tube end
to the ink overflow pan.
* Be careful not to allow the ink to drip from the
tube.
 CONFIDENTIAL

FW Series - Replacement Procedure of Pressurized/

[12] Negative Pressure Tanks (Old → Old Type)

(4) Connect the wire connector to the ink sensor for
the pressurized ink tank and hook the wires with
the hook.
Plug the connector
9. Draining the Colorless Ink
(1) Remove the forceps blocking the drain tube and
drain the colorless ink in the replaced, new ink
tank assembly (part A) into the ink overflow pan.
* Check that the colorless ink is draining.
* Wait until no colorless ink comes out.
* When replacing two or more color tanks, allow
the colorless 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).

Hook the wires

(5) Connect the wire connector for the ink circulation

pump and hook the wires with the hook.

Forceps

(2) Check that the front cover is open, turn ON the

power, and enter test mode.
Hook the When the following errors appear in test mode,
wires cancel the display.
• Z002-2125 / • Z002-2126
• Z002-2127 / • Z002-2128
• Z022-1255 / • W051-1301
Plug the connector

"With wires connected"

Negative pressure ink Pressurized ink

tank side tank side
 CONFIDENTIAL

FW Series - Replacement Procedure of Pressurized/

[13] Negative Pressure Tanks (Old → Old Type)

(3) Drive the ink circulation pump for the replaced,
new tank assembly in test mode and stop the
pump once no colorless ink comes out from the
end of the drain tube.
• CIRCULATION PUMP MOTOR K: TM092031
• CIRCULATION PUMP MOTOR C: TM092032
• CIRCULATION PUMP MOTOR M (R): TM092033
• CIRCULATION PUMP MOTOR Y: TM092034
(4) Connect the drain tube to the sealing port on
the ink overflow pan and tuck the tube in the slit
folding it in Z.
11. Attaching Covers and Closing the
Tower
(1) Fold the downstream tube for the external
filter circulation tank on the replaced, new tank
assembly and fix with the supplied wire band.
After fixing it, set it in the space between the tank
assemblies as shown in the figure below.
* Spares of the wire band are supplied (3 pcs).

Drain tube
Slit

10. Filling Ink

(2) In the reverse order of steps in section 1, close
(1) Switch the printer into head replacement
the ink tower unit, the engine PCB unit, and the
mode from test mode.
power supply unit and attach removed covers.
• 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 cover and turn ON the interlock.
(5) Turn on the power and wait until the initial ink
supply is completed (for approx. 7 min.).
(6) After the initial ink supply is completed, circulate
the inks in test mode (for approx. 10 min.).
• INK CIRCULATION ACTION: TM093068
 CONFIDENTIAL

FW Series - Replacement Procedure of Pressurized/

[14] Negative Pressure Tanks (Old → Old Type)

Supplied Parts List G. Head downstream tube Y; tank (1 pc)

A. Pressurized/negative pressure tank assembly; SU
(1 pc)

H. SOL_ORING_K (1 pc)

B. T_CLIP_5 (4 pcs)

Supplemental. Small pan-head screw, double-washer

M3x8 (4 pcs)

C. T_CLIP_5_SFT (7 pcs)

Supplemental. Binder (Wire band) (4 pcs)

D. Tube Φ8/Φ5; 300 (1 pc)

300 mm

E. Tube Φ8/Φ5; 135 (1 pc)

135 mm

F. Head downstream tube K; tank (1 pc)