OKI ES3640 MFP Component Replacement Manual

ES3640MFP / CX3641MFP

Component & Disassembly Guide

Disclaimer

Every effort has been made to ensure that the information in this document is complete, accurate, and up to date. The manufacturer assumes no responsibility

for the results of errors beyond its control. While all reasonable efforts have been made to make this document accurate and helpful as possible, we make no

warranty of any kind, expressed or implied, as to the accuracy or completeness of the information contained herein. For the most up-to-date service information

available, visit our website at www.okidata.com © Okidata Americas, Inc. 2008

Chapter 1

Component Locations and their Functions

1.1 Electrical Components

Control Panel

Fiery Control PCB

Engine Control Board

Registration Sensor Board

LED Relay Board

Imaging Unit Sensor Board

1.2 Printer Fans

Printer Fans

1.3 Solenoids and Clutches

Solenoids and Clutches

1.4 Motor Assemblies

Imaging Unit Drive Motors

Transfer Unit Motor

1.5 Machine Assemblies

Waste Toner Recovery

Registration Assembly

Eject Assembly

1.6 Sensors in the Printer

Sensors in the Printer

Motor Driver Board

Feeder Board

HVPS

LVPS

Front Sensor Board

Rear Sensor Board

Toner Motors

Duplex Drive Motors

MPT Tray

Tray 1 – Universal Feed Tray

Chapter 2

Printer Disassembly

2.1 Covers

Rear Cover

Lower Rear Cover

Right Rear Cover

Right Side Cover

Left Side Cover

Front Door

2.2 Paper Feed

MPT Tray

MPT Tray Level Sensor

MPT Home Position Sensor

MPT OHP Sensor

MPT Feed Out Sensor

MPT No Paper Sensor

MPT Feed Rollers

Tray 1 Paper Feed Unit

Tray 1 Paper Registration Motor

2.3 Internal Printer Components

Job Offset Assembly

Job Offset Motor

Job Offset Home Position Sensor

Right Upper Door Latch Assembly

Media Thickness Sensor

Temperature/Humidity Sensor

Eject Assembly

Exit Gate Solenoid

Fuser Exit Sensor and Actuator

Top Output Tray Stack Full Sensor

Side Output Tray Detect Sensor

Side Output Tray Stack Full Sensor

Upper Left Door Detect Sensor

Fuser Release Sensor

Registration Sensor Assembly

2.4 Printer Motors

Transfer Unit Motor

Toner Motors

Imaging Unit Motors

Automatic Density Control Sensor

Media Slack Sensor and Actuator

Registration Assembly

Registration Clutch

Waste Toner Auger Assembly

Waste Toner Container Full Sensor

Waste Toner Container Auger Rotation Sensor

Waste Toner Auger Rotation Sensor

Transfer Unit Belt Rotation Sensor

Lower Basket Assembly

Basket Assembly

LED Assembly

Registration Shutter Solenoid

Right Lower Door

Left Rear Cover

Left Front Cover

Upper Front Cover

Right Front Cover

Top Cover

Tray 1 Paper Feed Motor

Tray 1 Paper Lift Motor

Tray 1 Registration Clutch

Right Lower Door Detect Sensor

Tray 1 No Paper Sensor

Tray 1 Registration Sensor / Feed Out Sensor

Tray 1 Feeder Board

Tray 1 Feed Rollers

Side Output Tray

Fuser Motor

Waste Toner Motor

Imaging Unit Up/Down Mechanism

2.5 Electrical Components

Control Panel

Engine Control Board

Fiery Control Board

Card Cage Fan Duct

Card Cage Fan

Card Cage

HVPS Cover

High Voltage Power Supply

Housing Bias Assembly

Low Voltage Power Supply

LVPS Fan

LED Head

LED Relay Board

Top Cover Interlock Switch

Waste Toner Container Detect Switch

Right Upper Door Interlock Switch

Imaging Unit Fan

Transfer Unit Fan

Top Cover Fan

Fiery Control Board Fan

Paper Size Switch

Motor Driver Board

Imaging Unit Sensor Board

Toner Supply Camshaft

Imaging Unit Motor Mounting Plate

RFID Reader Board

RFID Antenna

Registration Sensor Board

Fuser Fan

Front Sensor Board

Rear Sensor Board

Chapter 3

Printer Engine Diagrams

3.1 Circuit Board Connectors

Engine Control Board

Motor Driver Board

LVPS

Imaging Unit Sensor Board

Front Sensor Board

Rear Sensor Board

Feeder Board

LED Relay Board

3.2 Wiring Diagram

Print Engine General Wiring Diagram

Front Sensor Board

Feeder Board

Rear Sensor Board

Registration

Motor Driver Board

LED Heads

HVPS

LVPS

Fuser

Imaging Unit Sensor Board

Control Panel

Chapter 1

Component Locations and their Functions

The following provides an overview of the major components and description

of their various functions within the printer.

Electrical Components

The following provides an overview of the major Printed Circuit Board

components

Fans

Location of Fans used to circulate air throughout the printer.

Solenoids and Clutches

Location of solenoids and clutches used to actuate various gates and rollers.

Motor Assemblies

Locations for all of the printer’s motors.

Machine Assemblies

Locations for all of the printer’s major assemblies.

Sensors in the Printer

Identifies the location of each sensor in the printer

1.1 Electrical Components

The following provides an overview of the major electrical components and description of

their various functions within the printer.

Front Sensor PCB

LED Relay PCB

Registration Sensor PCB

RFID Reader PCB

Rear Sensor PCB

RFID Antenna

Duplex Control PCB

Control Panel PCB

HVPS PCB

Imaging Unit Sensor PCB

Fiery Control / Image Processor PCB

Engine Control PCB

Motor Driver PCB

LVPS PCB

Control Panel

The Control Panel is the primary interface to the printer’s functions and includes the display,

keypad, and status LED.

Fiery Control PCB

The Fiery Control PCB receives host data through the USB or Ethernet port. The received

data is buffered and stored, and then sent to the print engine in a rasterized format. The

Fiery Control Board connects to the Engine Control Board directly.

The Fiery Control board contains:

• Memory – RAM

• Flash DIMM

• NVRAM - Control Panel and network settings.

• Configuration Chip - determines the printer configuration.

• Hard Drive

Engine Control Board

The Engine Control Board synchronizes the print process by controlling the LED Heads,

motors, fans, sensors, solenoids, clutches and Fuser temperatures. The Engine Control

Board also controls the voltages to the Imaging Units and the print speed to compensate for

changes in media and environmental conditions.

Major Functions:

• Communicates with the Fiery Control PCB

• Receives information from the sensors and/or switches.

• Generates the image based on information from the Fiery Control Board.

• Controls high-voltage sent to the Imaging Unit to perform charging development,

primary and secondary transfer.

• Distributes the low-voltage DC power from the Low-Voltage Power Supply.

Registration Sensor Board

Located in the Registration Sensor Assembly, the Registration Sensor Board includes the

two sensors that monitor color registration.

LED Relay Board

Distributes power from the LVPS to the four LED Heads.

Imaging Unit Sensor Board

The Imaging Unit Sensor Board communicates with the Engine Control Board and supplies

voltage for the two Imaging Unit Fans and Fuser Fan. The board also includes the four Low

Toner Sensors that monitor toner levels in the Imaging Units, and the Imaging Unit Position

sensor that detects the image drum Up / Down position.

• Low Toner Sensors [C] [M] [Y] [K] Detects level of toner in the Imaging Unit.

• Toner Cartridge in Sensors [C] [M] [Y] [K] Detects the presence of the Toner

Cartridge in the holder.

• The Up / Down Position Sensor Detects the Image Drum Up / Down position.

• Imaging Unit Drum Phase Sensors Detect the position of the Imaging Unit Drums.

Motor Driver Board

Located directly below the Imaging Unit motors, the Motor Driver Board receives +24 V

from the LVPS and distributes power and control signals to these devices:

• Imaging Unit Motors

• Toner Motors

• Waste Toner Motor

• Fuser Motor

• Tray 1 Paper Size Switches

Feeder Board

Located in the FDR Registration Unit, the Feeder Board communicates with the Motor Driver

Board and provides connections for these components:

• Registration Clutch #2

• Registration Sensor #2

• Feed-Out Sensor #2

• Tray 1 No Paper Sensor

• Tray 1 Door Interlock.

Integrated on the board are the Tray 1 Level Sensor and Tray 1 Low Paper Sensor.

HVPS

Located under the Transfer Unit and HVPS Cover, the HVPS supplies high-voltage to the

Transfer Unit and Imaging Units. The HVPS also provides connections for the Front Door

Interlock that disables +24V when opened, the Waste Toner Container Full, and Detect

Hall-effect sensors.

HVPS Imaging Outputs

LVPS

The LVPS supplies AC power from the power source to the Fuser heater. Generates and

supplies stable low-voltage DC power (+5 VDC, and +24 VDC) to be used for the logic and

other circuits within the printer. The LVPS includes the LVPS Board with attached Power

Switch, the AC Harness, a Fan, and the box enclosure.

LVPS Outputs

Front Sensor Board

Located under the Registration Roller #1, the Front Sensor Board communicates with the

Motor Driver Board and connects to these components:

• Media Thickness Sensor

• Registration Clutch #1

• Temperature/Humidity Sensor

• MPT Home Position Sensor

• OHP (Transparency) Sensor

• MPT Level Sensor

• MPT No Paper Sensor

Mounted directly on the board are the Registration Sensor #1 and Transfer Unit Entrance

Sensor.

Rear Sensor Board

Located behind the Rear Sensor Board Cover on the Exit Assembly, the Rear Sensor Board

communicates with the Engine Control Board and connects to these components:

• Fuser Exit Sensor

• Stack Full Sensors for Top and Side Output Trays

• Job Offset Position Sensor

• Side Output Tray Detect Sensor

• Right Door Detect Sensor

• Exit Gate Solenoid

• Mounted directly on the board is the Offset Paper End Sensor.

1.2 Fans

A number of fans are used to circulate air throughout the printer.

Caution: when servicing a fan, note the orientation of the Fan label before removal.

• Top Cover Fan located above the Cyan LED Head in the Top Cover

• Card Cage Fan located behind the Right Rear Cover

• Fuser Fan located at the upper left rear corner underneath the Top Cover

• Imaging Unit Fan located behind the Control Panel

• Transfer Unit Fan located below the Imaging Unit Motors

• Fiery Control PCB Fan located in the Card Cage

• LVPS Fan located in the LVPS

• Duplex Unit Fan inside the Duplex Unit

***** Use the “Motor Clutch Test” in Chapter 2 to test fan operation*****

Top Cover Fan

LVPS Fan

Card Cage Fan

Transfer Unit

Fan

Fiery Controller / Image Processor Fan

Fuser Fan

Image Drum

Fan

Duplex Fan

1.3 Solenoids and Clutches

A number of solenoids and clutches are used to actuate various gates and rollers. The figure

below shows the position of all the solenoids and clutches in the Print Engine.

***** Use the “Motor Clutch Test” in chapter 2 to test Solenoid - Clutch operation*****

Exit Gate Solenoid

Registration Shutter Solenoid

Duplex Gate Solenoid Registration Clutch 2

Registration Clutch 1

1.4 Motor Assemblies

The following illustration shows the location for all the printer’s motors.

Imaging Unit Drive Motors

The Imaging Unit Motors drive the Imaging Unit drums, toner Agitation Bars and Agitation

Gears. Imaging Unit drive varies depending on the print mode. In addition to the developing

components, the Cyan Imaging Unit Motor uses an Up / Down mechanism to raise the CMY

Imaging Units during monochrome printing. When the Cyan Imaging Unit Motor rotates

(CCW), the Up / Down Mechanism slides to the left and, as indicated in the figure below,

each Imaging Unit moves down for color printing. When the Cyan Imaging Unit Motor

rotates (CW), the Up / Down Mechanism slides to the right, the CMY Imaging Units move up

for black and white printing.

* Use the “Motor Clutch Test” in the Service & Troubleshooting Guide to test Motor operation*

Job Offset Motor

Transfer Unit Motor

Duplex Motors

Waste Toner Motor

Feed Motor

Lift Motor

Imaging Drum Motors

Registration Motor

Fuser Motor

T

oner Motors

ID Unit Operations during Color Printing

ID Unit Operations during Monochrome Printing

Transfer Unit Motor

The Transfer Unit motor turns clockwise driving the Transfer Unit belt. Inside the Transfer

Unit are four Transfer Rollers located just under each Imaging Unit drum. When the Transfer

Unit Motor and Imaging Unit Motors are activated, they carry the paper on the transfer belt

to the Fuser. The voltages applied to the Transfer Rollers attract the toner image from the

Imaging Unit drum to the media.

***** Use the “Motor Clutch Test” in Chapter 2 to test Motor operation*****

Toner Motors

The CM and YK Toner Motors are mounted above the Imaging Unit Motors and drive the

Toner Cartridge Supply Augers and Agitation Springs to deliver toner to the Imaging Units.

Transfer Unit Motor

T

oner Motors

Duplex Drive Motors

Two motors are used to capture and transport paper in the Duplex Unit. Duplex Motor A

drives the Entrance Roller CCW to capture paper, then CW to drive the media into the

Transport Rollers. Motor B uses a series of belts to drive the four Transport Rollers that

move media to the Registration Assembly.

***** Use the “Motor Clutch Test” in Chapter 2 to test Motor operation*****

Duplex Motor B

Duplex Motor A

1.5 Machine Assemblies

Waste Toner Recovery

Waste toner recovery moves the toner collected from the Imaging Unit drums and Transfer

Unit belt to the Waste Toner Container located at the front of the printer. Driven by the

Waste Toner Motor, separate Augers in the Waste Toner Manifold and Waste Toner Duct pull

toner through a tube to the Waste Toner Container. Waste toner is moved within the

Container by another Auger driven by the Waste Toner Motor.

Status of the Waste Toner container is monitored by the Engine Control Board. The Engine

Control Board receives count signals from the Waste Toner container Auger Rotation Sensor

located behind the Right Front Cover. This Hall-Effect sensor is activated each time a small,

magnetic disk, embedded in the Container auger gear, passes in front of the sensor. The

auger revolutions are converted into a life count.

• Waste Toner Container detect Switch detects the presence of the Waste Toner

Container.

• Waste Toner Container Full Sensor detects when the Waste Toner Container is full.

• Waste Toner Container Auger Rotation Sensor detects revolutions of the Container

auger.

• Waste Toner Auger Rotation Sensor detects revolutions of the manifold auger.

• Waste Toner Motor drives augers in the Waste Toner Manifold, Waste Toner Duct,

and Waste Toner Container.

***** Use the “Motor Clutch Test” in Chapter 2 to test Motor operation*****

Waste Toner Auger Assembly

T

ransfer Unit Waste Toner Chute

Waste Toner Container

Image Unit Waste Toner

Chutes

Registration Assembly

Shown in the following figure are the components associated with the Registration Assembly.

• MPT Home Position Sensor detects the position of the Feed drive.

• Registration Sensor #1

• Detects when the media’s leading edge has reached the Registration Rollers.

• Registration Rollers #1

• Driven by the Registration Motor through the Registration Clutch, the

Registration Rollers work to correct media skew and transport media to the

Transfer Unit belt.

• Registration Clutch #1

• Transfers drive from the Registration Motor to the Registration Rollers.

• Transfer Unit Entrance Sensor

• Detects the arrival of the media at the Transfer Unit.

• Media Thickness Sensor

• Produces a signal that varies dependent on media thickness.

• Temperature/Humidity Sensor

• Monitors environmental conditions surrounding the printer.

• Front Sensor Board

• Communicates the status of MPT and Registration Assembly sensors to the

Motor Driver Board.

Transfer Unit Entrance Sensor

Media Thickness Sensor

T

emperature Humidity Sensor

MPT Home Position Sensor

Registration Rollers #1

Registration Clutch #1

Front Sensor Board

Registration Sensor

Eject Assembly

The Eject Assembly uses rollers, solenoids, sensors, and diversion gates to handle media exiting

the Fuser.

Eject Assembly components include:

• Exit Gate - The Exit Gate switches the paper path. When the Exit Gate is in its

resting position, paper is fed to the Top Output Tray. When it is lowered by

the Exit Gate Solenoid, paper is fed to the Side Output Tray or Duplex Unit.

• Exit Gate Solenoid - Switches the paper discharge path between the Top and

Side Output Trays.

• Side Output Tray Full Stack Sensors - These sensors use an actuator to detect

when the Top or Side Output Tray is full.

• Fuser Exit Sensor - The Fuser Exit Sensor detects whether paper remains in

the output rollers.

• Door Detect Sensor - Detects whether the Door is open or closed.

• Side Output Tray Detect Sensor - Detects whether the Side Output Tray is

open or closed.

• Offset Home Position Sensor - The Offset Home Position Sensor detects the

roller position.

• Job Offset Trailing Edge Sensor - Detects the trailing edge of the media as it

leaves the Eject Assembly.

• Exit Rollers - Driven by the Fuser Motor, the Exit Rollers transport media from

the Fuser through the Eject Assembly.

• Duplex Gate - Actuated by the Duplex Gate Solenoid in the Duplex Unit, the

Duplex Gate directs media through the upper portion of the Duplex Unit and

returns it to the Registration Assembly for printing on side 2.

Eject Assembly

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