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Table of Contents

Summary of Contents for Oki ES3640MFP

Page 1 ES3640MFP / CX3641MFP Component & Disassembly Guide © 2008 OkiData Americas, Inc. 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.
Page 2 Chapter 1 Component Locations and their Functions Electrical Components Motor Driver Board Control Panel Feeder Board Fiery Control PCB HVPS Engine Control Board LVPS Registration Sensor Board Front Sensor Board LED Relay Board Rear Sensor Board Imaging Unit Sensor Board Printer Fans Printer Fans Solenoids and Clutches...
Page 3: Printer Disassembly
Chapter 2 Printer Disassembly Covers Right Lower Door Rear Cover Left Rear Cover Lower Rear Cover Left Front Cover Right Rear Cover Upper Front Cover Right Side Cover Right Front Cover Left Side Cover Top Cover Front Door Paper Feed Tray 1 Paper Feed Motor MPT Tray Tray 1 Paper Lift Motor...
Page 4: Electrical Components
Electrical Components Imaging Unit Fan Control Panel Transfer Unit Fan Engine Control Board Top Cover Fan Fiery Control Board Fiery Control Board Fan Card Cage Fan Duct Paper Size Switch Card Cage Fan Motor Driver Board Card Cage Imaging Unit Sensor Board HVPS Cover Toner Supply Camshaft High Voltage Power Supply...
Page 5: Wiring Diagram
Chapter 3 Printer Engine Diagrams 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 Wiring Diagram Print Engine General Wiring Diagram Front Sensor Board Feeder Board Rear Sensor Board Registration...
Page 6: Solenoids And Clutches
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.
Page 7 1.1 Electrical Components The following provides an overview of the major electrical components and description of their various functions within the printer. LED Relay PCB Registration Sensor PCB RFID Reader PCB Front Sensor PCB Rear Sensor PCB RFID Antenna Duplex Control PCB Control Panel PCB Fiery Control / Image Processor PCB Imaging Unit Sensor PCB...
Page 8: Control Panel
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.
Page 9: Imaging Unit Sensor Board
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.
Page 10 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.
Page 11: Front Sensor Board
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 •...
Page 12 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 •...
Page 13 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. Registration Clutch 1 Exit Gate Solenoid Duplex Gate Solenoid Registration Clutch 2 Registration Shutter Solenoid...
Page 14: Imaging Unit Drive Motors
1.4 Motor Assemblies The following illustration shows the location for all the printer’s motors. Toner Motors Job Offset Motor Imaging Drum Motors Fuser Motor Registration Motor Duplex Motors Transfer Unit Motor Lift Motor Feed Motor Waste Toner Motor Imaging Unit Drive Motors The Imaging Unit Motors drive the Imaging Unit drums, toner Agitation Bars and Agitation Gears.
Page 15 ID Unit Operations during Color Printing ID Unit Operations during Monochrome Printing...
Page 16: Transfer Unit Motor
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.
Page 17: Duplex Drive 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.
Page 18: Machine Assemblies
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.
Page 19: Registration Assembly
Registration Assembly Shown in the following figure are the components associated with the Registration Assembly. Temperature Humidity Sensor Transfer Unit Entrance Sensor Media Thickness Sensor Registration Clutch #1 Front Sensor Board Registration Sensor MPT Home Position Sensor Registration Rollers #1 •...
Page 20 Eject Assembly The Eject Assembly uses rollers, solenoids, sensors, and diversion gates to handle media exiting the Fuser. Eject Assembly 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.
Page 21 MPT Tray The (MPT) Tray feeds standard and custom size media into the printer. The printer’s Feed Motor, shared with Tray 1, drives the (MPT) Feed Roller to feed media from the tray. (MPT) components include: • Feed Rollers (Feed, Retard, and Pick-up) - Transport media from MPT Tray to the Registration Assembly.
Page 22 Tray 1 - Universal Feed Tray • Level Sensor - The Level Sensor uses an actuator to determine whether paper in the tray is lifted to the optimum feeding position. When the flag of the actuator leaves the sensing area, the sensor detects that the paper has been lifted. •...
Page 23: Sensors In The Printer
1.6 Sensors in the Printer The following illustrations identify the location of each sensor. ***** Use the “Switch Scan Test” in Chapter 2 to test Sensor operation***** Toner Supply Cyan, Magenta Sensors Color Registration Sensors Low Toner Sensors Toner Supply Yellow, Black Sensors Imaging Unit Up / Down Sensor Waste Toner Auger Rotation Sensor Waste Toner Container...
Page 24 The diagram below identifies the paper feed sensors. Job Offset Top Output Tray Trailing Edge Stack Full Sensor Sensor Side Output Tray Side Output Tray Stack Full Sensor Detect Sensor Job Offset Home Position Sensor Feed Out Sensor Transfer Unit Entrance Paper Size Switch Sensor...
Page 25: Sensor Functions
Sensor Functions The following table lists the function of each sensor. Sensor Function Sensor State Top Output Tray Stack Full Sensor Detects the Top Output Tray stack height. On = not full Off = full On = not full Side Output Tray Stack Full Sensor Detects the Side Output Tray stack height.
Page 26 On: media present Registration Sensor #1 Detects media at Registration Roller #1. Off: media absent On: media present Duplex Entrance Sensor Detects media entering the Duplex Unit. Off: media absent Detects the trailing edge and signals the Duplex Gate Solenoid On: media present Duplex Reverse Sensor to switch position.
Page 27: Parts Of The Printer
Chapter 2 Printer Disassembly The following details the disassembly of the printer unit. For re-assembly follow the procedure in reverse order Parts of the Printer Front View 1 Top Cover Latch 2 Control Panel 3 Paper Tray 1 4 Front Door 5 Paper Level Indicator 6 Top Output Tray 7 Right Upper Door...
Page 28: Lower Rear Cover
2.1 Covers Rear Cover Loosen the 2 captive thumbscrews. Remove the 2 (metal, 6 mm) screws that secure the Rear Cover to the frame. Lower Rear Cover Remove 5 (metal, 10 mm) screws from the Lower Rear Cover. Using a screwdriver, release the 2 tabs located near the bottom of the Lower Rear Cover. Remove the Lower Rear Cover.
Page 29: Right Rear Cover
Right Rear Cover Open the Top Cover. Open Right Lower Door. Remove 2 (metal, 6 mm) screws from the Right Rear Cover. Release the 3 guides and remove the cover. Right Side Cover Removal of the Right Side Cover from printers with optional Hi Cap Feeders installed requires the right hand side of the print engine to be lifted approximately three inches to clear the lower tray.
Page 30: Left Side Cover
Left Side Cover Open the Top Cover. Remove the Duplex Unit, if present. Remove 4 (metal, 10 mm) screws securing the Left Side Cover. Using a screw driver, release the center tab on the bottom of the Left Side Cover. Flex the Left Side Cover slightly and pull down on the cover to release it from the printer.
Page 31: Right Lower Door
Right Lower Door Remove the Right Side Cover. Open Right Lower Door. Remove the Right Lower Door Chute by sliding the chute to the left and gently prying the left hinge point from the Right Lower Door pivot. Slide Right Lower Door to the left to release the bosses from the holes in the frame. Left Rear Cover Open the Top Cover.
Page 32: Upper Front Cover
Left Front Cover Open the Top Cover and lift the Basket Assembly. Open the Front Door. Remove the Waste Toner Container, if present, and then insert the Waste Toner Plug as shown on the Container label. Remove 1 (metal, 6 mm) screw that secures the left side Stopper Strap on the Front Door. Remove 2 (metal, 10 mm) screws securing the Left Front Cover.
Page 33: Top Cover
Right Front Cover Caution: The Waste Toner Container Auger Rotation Sensor is mounted in the Right Front Cover. Use care not to damage the sensor wiring during the removal process. Open Right Upper Door. Remove the Waste Toner Container if installed. Remove the Front Door.
Page 34: Paper Feed
2.2 Paper Feed MPT Tray Open the Top Cover. Remove the Front Sensor Board Cover. Disconnect 2 connectors on the Front Sensor Board. Caution: The hinges are not captive to the tray. In the following steps, use care not to drop the hinges Open Right Upper Door Remove 2 (metal, 6 mm) screws, one at each hinge, that secure either side of the MPT Tray.
Page 35 Release the wiring from the opening in the Registration Assembly. If the connector hangs inside the Registration Assembly, tape the connector parallel to the wiring to facilitate removal. Replacement Note: When replacing the MPT hinges, replace the rear hinge first. MPT Tray Level Sensor Two non-captive springs are installed under the Feed Roller Assembly cover.
Page 36 MPT Home Position Sensor Remove the Registration Assembly. Release 2 hooks that secure the gear cover to the back of the Registration Assembly. Release the 3 hooks that secure the sensor to the Registration Assembly, and then push the sensor through the opening to the back of the assembly.
Page 37 MPT Feed Out Sensor Open Right Upper Door. Remove the Sensor Cover from the back of the MPT Tray. Disconnect the sensor from the harness. Release the hooks that secure the sensor to the MPT Tray. MPT No Paper Sensor Note: A non-captive spring is installed in the Rear Chute to tension the Retard Roller.
Page 38 MPT Feed Rollers Partially open MPT Tray. Rotate the 2 levers 90 degrees to unlock the Feed Roller Assembly linkage from MPT Tray Links. Raise the Feed Roller assembly to access the Pick-up and Feed Rollers. Open the Retard Roller Access Door. Remove the Pick-up Roller by gently prying the left end away from the housing.
Page 39 Remove the Feed Roller Paper Guide to provide space to remove the rollers. Remove the Feed and Retard Rollers by releasing the hook and sliding the roller off the shaft. Replacement Note: Match each replacement roller to the one being removed. All three rollers are unique. Tray 1 Paper Feed Unit Note If optional Hi Cap Feeder is installed, either remove the printer from the HCF or place a ream of paper, or similar...
Page 40 Tray 1 Paper Registration Motor Remove the Tray 1 Paper Feed Unit. Release the motor harness from the clamp. Disconnect the Registration Motor connector from the harness. Remove 2 (metal, 6 mm) screws that secure the Registration Motor to the Feeder. Tray 1 Paper Feed Motor Remove the Tray 1 Paper Feed Unit.
Page 41 Tray 1 Registration Clutch Remove the Tray 1 Paper Feed Unit. Remove the E-clip that secures the clutch to the Registration Roller. While holding the anti-rattle spring, remove the clutch from the roller shaft. Right Lower Door Detect Sensor The Right Lower Door Detect Sensor is mounted on a carrier located beneath the Registration Rollers near the clutch.
Page 42 Release the hook that secures the sensor holder to the feeder. Right Lower Door Detect Switch Tray 1 Feed Unit Turn the sensor holder over, and then release the hooks that secure the sensor to the carrier. Disconnect the sensor connector. Tray 1 No Paper Sensor Remove the Tray 1 Paper Feed Unit.
Page 43 Tray 1 Registration Sensor / Feed Out Sensor Remove the Tray 1 Paper Feed Unit. Remove the Registration Clutch. Remove the Feeder Board Cover. Remove 4 (metal, 6 mm) screws that secure the feeder top. Feed Unit (Top) Tray 1 Feed Unit Separate the feeder top and then turn the top over.
Page 44 Turn the feeder top upright, and the release the 2 hooks that secure the sensor housing to the top of the feeder. Feed Out Sensor Registration Sensor Sensor Cover Tray 1 Feed Unit Release the hooks that secure the sensor in the housing. Disconnect the sensor connector, and then remove the sensor.
Page 45 Tray 1 Feed Rollers Note: Feed Roller (Pick-up, Feed. Retard) removal is identical for all Universal Trays. However, each roller is unique. Match each replacement roller to the roller being removed. Remove Tray 1. Open Right Lower Door. Release the hook that secures each roller to the shaft Side Output Tray Open the Top Cover.
Page 46 2.3 Internal Printer Components Job Offset Assembly Note: There are two springs on top of the Job Offset Assembly that are not captured. Use care not to lose these springs. Remove the Top Cover. Release the Job Offset Motor harness from the guides at the rear of the LED Assembly (4 red wires). Release 2 hooks securing the Job Offset Assembly to the Top Output Chute.
Page 47: Job Offset Motor
Job Offset Motor Remove the Job Offset Assembly. Remove the 1 (black, plastic, 10 mm) that secures the Job Offset Gear Cover. Release the 4 hooks that secure the Job Offset Motor mounting plate to the Job Offset Assembly. Remove the 1 (metal, 6 mm) screw that secures the Job Offset Motor to the mounting plate to remove the motor. Job Offset Home Position Sensor Remove the 6 hooks that secure the Rear Sensor Board Cover to the Eject Assembly.
Page 48 Right Upper Door Latch Assembly Open the Top Cover. Open the Basket Assembly. Open Upper Right Door. Release the 3 hooks that secure the Right Upper Door Interlock Right Upper Door Interlock Switch Hook Remove the 5 (metal, 6 and 10 mm) screws that secure the latch to the frame. Gently pull the Upper Front Cover forward to release the latch assembly from the frame.
Page 49: Media Thickness Sensor
Media Thickness Sensor Open the Top Cover. Open the Basket Assembly. Remove the sensor cover by lifting the front tab slightly and pushing the cover to the rear. Disconnect the sensor connector. Remove the 2 (metal, 6 mm) screws that secure the sensor and holder to the frame. Replacement Note: Make sure the sensor’s gears are engaged and the holder is aligned to the bosses on the frame before tightening the screws.
Page 50 Eject Assembly Open the Top Cover. Remove the Duplex Unit. Remove the Fuser. Remove the Side Output Tray. Release the 6 hooks and 3 tabs that secure the Rear Sensor Board Cover. Disconnect connector from the Rear Sensor Board. Carefully remove harness from the Eject Assembly. This requires that the connector be fed through a hole provided at the rear of the Eject Assembly.
Page 51: Exit Gate Solenoid
Exit Gate Solenoid Remove the Eject Assembly. Disconnect the solenoid connector from the Rear Sensor Board. Feed the solenoid harness out the opening at the front of the Eject Assembly. Release the hook that secures the Exit Gate Solenoid to the Eject Assembly. Fuser Exit Sensor and Actuator Remove the Eject Assembly.
Page 52: Side Output Tray Detect Sensor
Side Output Tray Detect Sensor Remove the Eject Assembly. Release the 2 hooks that secure the Top Output Tray Stack Full Sensor cover. Disconnect the Top Output Tray Stack Full Sensor. Release the wire that surrounds the sensor. Release the 2 upper hooks of the Outer Exit Chute. Separate the outer and inner chutes enough to disconnect the Side Output Tray Stack Full Sensor.
Page 53: Side Output Tray Stack Full Sensor
Side Output Tray Stack Full Sensor Remove the Eject Assembly. Release the 2 hooks that secure the Top Output Tray Stack Full Sensor cover. Disconnect the Top Output Tray Stack Full Sensor. Release the wire that surrounds the sensor. Release the 2 upper hooks of the Outer Exit Chute. Separate the outer and inner chutes enough to disconnect the Side Output Tray Stack Full Sensor.
Page 54 Upper Left Door Detect Sensor Remove the Eject Assembly. Release the 2 hooks that secure the Top Output Tray Stack Full Sensor cover. Disconnect the Top Output Tray Stack Full Sensor. Release the wire that surrounds the sensor. Release the 2 upper hooks of the Outer Exit Chute. Separate the outer and inner chutes enough to disconnect the Side Output Tray Stack Full Sensor.
Page 55: Fuser Release Sensor
Fuser Release Sensor Remove the Duplex Unit. Release the 3 hooks that secure the sensor to the frame. Disconnect the Fuser Release Sensor connector. Registration Sensor Assembly Remove the Front Door. Remove the Waste Toner container, if installed. Remove the Left Front Cover.
Page 56 Registration Shutter Solenoid Remove the Registration Sensor Assembly. Remove the E-clip that secures the Registration Shutter linkage to the assembly. Disconnect the Registration Shutter Solenoid connector. Remove 1 (metal, 6 mm) screw, with washer, securing the Registration Shutter Solenoid to the assembly. Automatic Density Control Sensor Note: The Registration Shutter return spring is not captive to the shutter.
Page 57: Media Slack Sensor And Actuator
Media Slack Sensor and Actuator Remove the Registration Sensor Assembly. Remove the 3 (metal, 6 mm) screws that secure the sensor and actuator to the Registration Sensor Assembly. Remove the 1 (metal, 6 mm) screw that grounds the resistor to the assembly. Disconnect the sensor connector.
Page 58: Registration Clutch
Registration Assembly Open the Top Cover. Open the Front Door. Open the Upper Right Door. Open the Basket Assembly. Remove the Duplex Unit. Remove MPT Tray. Remove the Upper Right Door Latch Assembly. Remove 1 (metal, 10 mm) screw that secures the Registration Assembly. Release the wiring from the guides in the Registration Assembly.
Page 59: Waste Toner Auger Assembly
Waste Toner Auger Assembly Remove the Waste Toner Container if installed. Remove the Duplex Unit. Release 4 hooks that secure the Waste Toner Motor Cover. Release 1 hook Remove 4 (black, plastic 6 mm) screws connecting the Waste Toner Manifold to the Basket Assembly. Open the Basket Assembly to release the manifold from the basket.
Page 60 Waste Toner Container Full Sensor The Waste Toner Container Full Sensor is located in the sensor housing attached directly above the Waste Toner Container Auger drive. Open the Top Cover. Remove the HVPS Cover. Disconnect the Connector from the HVPS Open the Front Door.
Page 61: Waste Toner Auger Rotation Sensor
Waste Toner Auger Rotation Sensor The Waste Toner Auger Rotation Sensor is located at the right end of the Waste Toner Manifold. The sensor is connected to the Motor Driver Board. Open the Top Cover. Open the Basket Assembly. Remove 1 (metal, 6 mm) screw that secures the sensor holder. Disconnect the sensor from the harness.
Page 62: Lower Basket Assembly
Lower Basket Assembly Remove 4 (Black, plastic 6 mm) screws that secure the Waste Toner Manifold to the Lower Basket Assembly. Remove 2 E-rings that secure the hinges on either side of the Lower Basket Assembly. Release the Spring from the Upper Basket Assembly at the left, rear of the arm. Remove the Hinge Pins to remove the Lower Basket Assembly.
Page 63: Basket Assembly
Basket Assembly Note: Take note of the Torsion Spring position before removing the Inner Shaft. Remove the Top Cover. Remove the Right Rear Cover. Remove the Left Rear Cover. Remove the Fuser Fan and Fan duct. Remove the Job Offset Assembly. Remove the Top Output Chute.
Page 64 Lower the LED Assembly to remove 2 (metal, 10 mm) screws that secures each sector gear located at either side of the LED Assembly. Release the Torsion Springs that supply tension to the Lower Basket Assembly. Use a second screwdriver as a stop to prevent the spring from snapping upwards and striking the LED Heads.
Page 65 Remove the Inner Shaft in the direction of the arrow (towards the MPT). Remove 3 (metal, 10 mm) screws that secure each Outer Damper to the frame. Release the bushings from the flange on the frame to remove the Basket Assembly.
Page 66: Led Assembly
Replacement Note: Observe these notes as you reassemble the Basket Assembly. Replace the screws that secure the Inner Shaft to the Dampers before replacing the E-ring at the end. Align the Guide Rollers at the end of each Lower Basket Assembly arm in the tracks before securing the Dampers. Move the outer stops to the rear before installing the Pins.
Page 67 Make note of the Torsion Spring position, and then remove the Outer Shaft by pushing in the direction of the arrow. Remove LED Assembly. Replacement Note: Transfer all the LED and RFID components to the replacement assembly. Make sure the contacts under the outer shaft and springs are properly placed in their notches.
Page 68: Printer Motors
2.4 Printer Motors Transfer Unit Motor Open the Top Cover. Remove the Front Door. Remove the Waste Toner Container, if installed. Remove the Left Front Cover. Position the Control Panel parallel to the floor. Disconnect the motor connector. Remove the 2 (metal, 6 mm) screws securing the motor. Toner Motors The Toner Motor supporting the YK Imaging Units is at the left.
Page 69: Imaging Unit Motors
Imaging Unit Motors The Imaging Unit Motors (CMYK) are all mounted to single mounting plate by 2 (metal, 6 mm) screws. In addition to the screws, each motor has a corresponding connection to the Motor Driver Board. Use the following procedure to remove one or all four Imaging Unit Motors.
Page 70: Waste Toner Motor
Waste Toner Motor Release the 4 hooks that secure the Waste Toner Motor Cover. Disconnect the Waste Toner Motor connector from the Waste Toner Motor harness. Remove 2 (metal, 6 mm) screws that secure the motor to the frame. Motor Connector...
Page 71 Imaging Unit Up / Down Mechanism The Imaging Unit Up /Down mechanism uses two Lift racks, front and back, to lift the color Imaging Units away from the Transfer Unit belt during monochrome printing. Rear Up / Down Rack Remove the Imaging Unit Sensor Board.
Page 72 Release the hook and 4 tabs that secure the Up/Down Cover to the frame, and then remove the cover. Front Up /Down Cover Front Up / Down Rack Move the Up/Down Rack to the right to clear the gear set, and then remove the Up/Down Rack...
Page 73 2.5 Electrical Components Control Panel Release the 2 hooks closest to the printer from underneath the Control Panel. Lift up on the part of the panel closest to the printer to remove the Control Panel faceplate. Remove 1 (metal, 6 mm) screw that secures the ribbon cable. Disconnect the ribbon cable from the Control Panel Board.
Page 74 Fiery Control Board Remove the Rear Cover. Disconnect the Fan connector. Remove 6 (metal, 6 mm) screws securing the Fiery Control Board. Remove the Fiery Control Board and Rear Panel. ES3640 Fiery Removal CX3641Fiery Removal Remove the Fan Assembly Remove the BY3 PCB Remove the Fiery Controller...
Page 75: Card Cage Fan Duct
Card Cage Fan Duct Open the Top Cover. Open Right Lower Door. Remove the Right Rear Cover. Release the 2 hooks, top and bottom, that secure the Fan Duct to the Fan Housing. Remove the left side of the Card Cage Fan Duct from the printer to release the 2 tabs from the Card Cage. Replacement Note: Insert the right side of the Card Cage Fan Duct into the printer first to engage the 2 tabs.
Page 76: Hvps Cover
Card Cage Remove the Rear Cover. Remove the Lower Rear Cover. Remove the Right Rear Cover. Remove the Card Cage Fan Duct. Remove the Engine Control Board. Remove the Fiery Control Board. Remove 11 (metal, 6 mm) screws securing the card cage to the printer. Remove 1 (metal, 6mm) screw that secures the LED Head cable clamp and guide block.
Page 77: High-Voltage Power Supply
High Voltage Power Supply Remove the HVPS Cover. Disconnect 4 connectors from the HVPS. Remove 2 (metal, 6 mm) screws and carefully slide the board to the rear to clear the Housing Bias Assembly. Housing Bias Assembly Caution: The Transfer Unit Belt Rotation Sensor is mounted in the Housing Bias Assembly. Use care not to damage the sensor wiring during the removal process.
Page 78: Low Voltage Power Supply
Low Voltage Power Supply Remove 14 (metal, 6 mm) screws securing the power supply enclosure. Lift the Power Switch Link Arm from the Power Switch on the LVPS. Disconnect 4 connections to the LVPS and remove the LVPS enclosure. Remove the LVPS Fan. Remove the 2 (metal, 10 mm) screws that secure the AC Inlet to the LVPS enclosure.
Page 79 LVPS Fan Remove the LVPS enclosure. Disconnect the Fan connector. Release the Fan harness from the insulation film. Remove 2 (metal, 30 mm) screws securing the fan to the enclosure to remove it. LED Head Open the Top Cover. Release the front tab of the LED Head from the holder by gently pushing the LED Head towards the rear while pulling the holder forward.
Page 80: Led Relay Board
LED Relay Board Remove the Top Cover. Remove the Rear Cover. Disconnect the 4 LED Heads from the Engine Control Board CC, YY, MM, and KK connectors. Disconnect the RFID Reader Board ribbon cable from the Engine Control Board RFID connector. Remove 1 (metal, 6 mm) screw that secures the cable clamp holding the LED Head and RFID Reader Board wiring.
Page 81 Remove 2 (metal, 6 mm) screws that secure the Control Panel mounting. Remove the switch by pulling the Control Panel mount away from the frame, and then shift the switch holder first to the right, then down. Feed the wiring through to the front to remove the switch. Spread the 2 hooks that secure the switch to the holder.
Page 82 Waste Toner Container Detect Switch An actuator on the back of the Front Door penetrates the Waste Toner Container to activate a switch mounted in a sensor housing attached to the frame. Open the Top Cover. Remove the HVPS Cover. Disconnect connector from the HVPS Open the Front Door.
Page 83 Right Upper Door Interlock Switch An actuator mounted on the Right Upper Door Latch Assembly penetrates the frame to activate a micro-switch mounted above the Card Cage Fan. Remove the Card Cage Fan Duct. Disconnect the connector from the Motor Driver Board. Right Upper Door Interlock Switch Remove 1 screw that secures the micro-switch to the frame.
Page 84: Transfer Unit Fan
Transfer Unit Fan The Transfer Unit Fan is located directly behind the Cyan Imaging Unit Motor. Remove the Rear Cover. Remove the Right Rear Cover. Remove the Card Cage Fan Duct. Remove the Card Cage. Remove 2 (metal, 6 mm) screws that secure the Cyan Imaging Unit Motor. Remove 2 (metal, 23 mm) screws with washers that secure the Transfer Unit Fan to the frame.
Page 85 Rotate the Top Cover Latch upward, and then remove the 1 (black, plastic 6 mm) screw that secures the front of the Cyan LED Holder. Move the Cyan LED Holder to the right to allow sufficient clearance to remove the duct from the LED Assembly. Release 2 hooks that secure the diffuser to the duct.
Page 86 Disconnect the Top Cover Fan connector (P/J482) on the LED Relay Board cover. Replacement Note Route the fan wiring through the opening in the Cyan LED Holder and lace the wiring back into the guides provided in the duct. Also, install the fan with the label facing towards the Transfer Unit. Fiery Control Board Fan Open the Rear Cover.
Page 87: Paper Size Switch
Paper Size Switch Remove the Tray. Open the Top Cover. Remove the Right Rear Cover. Remove the Card Cage Fan Duct. Remove the LVPS enclosure. Release the 2 hooks that secure the Paper Size Switch Holder to the frame. The four springs are attached to the holder.
Page 88: Motor Driver Board
Motor Driver Board Remove the Rear Cover. Remove the Right Rear Cover. Remove the Card Cage Fan Duct. Remove the Card Cage. Remove 2 (metal, 6 mm) screws that secure the Magenta Imaging Unit Motor. Remove 2 (metal, 6 mm) screws that secures the Yellow Imaging Unit Motor. Remove the (Yellow) and (Magenta) connections from the Motor Driver Board.
Page 89 Remove 1 (metal, 6 mm) screw on each of the 4 Imaging Unit Drum Phase Sensors and release the sensors from their retainers. Up/Down Sensor Drum Phase Sensors Release the wiring from the guide just above the Cyan Imaging Motor. Disconnect the Fan connector from the right side of the board.
Page 90: Toner Supply Camshaft
Toner Supply Camshaft The Toner Supply Camshafts are mounted in the Toner Supply Housing. Follow the Imaging Unit Sensor Board removal procedures through Step 13 to remove the Toner Supply Housing from the printer. Remove the camshaft by releasing it from the Toner Supply Housing. Imaging Unit Motor Mounting Plate Remove the Motor Driver Board.
Page 91: Rfid Reader Board
RFID Reader Board Remove the Top Cover. Disconnect the ribbon cable from the RFID Reader Board. Disconnect the 4 RFID Antenna connectors from the RFID Reader Board. Remove the 2 (metal, 6 mm) screws that secure the RFID Reader Board Cover to the top of the LED Assembly. Flip the cover over, and then remove the 2 (metal.
Page 92: Fuser Fan
Registration Sensor Board The Registration Sensor Board includes the Front Color Registration Sensor attached by a ribbon cable, the Rear Color Registration Sensor integrated onto the board, the interface for the ADC Sensor, and the Transfer Unit Belt Slack Sensor. Replacement of either Color Registration Sensor requires replacement of the board. Note: The Color Registration Sensors are protected from the Transfer Unit belt by small, transparent covers.
Page 93: Rear Sensor Board
Move the Registration Sensor #1 and Transfer Unit Entrance Sensor Actuators to allow clearance, and then release the 3 hooks that secure the board to the assembly. Replacement Note: Use a piece of non-conductive tape to retain the spring while replacing the board. Remove the tape just prior to snapping the board into the hooks.
Page 94 Chapter 3 Print Engine Diagrams 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 Wiring Diagram Print Engine General Wiring Diagram Front Sensor Board Feeder Board Rear Sensor Board Registration...
Page 95 Engine Control Board To Yellow LED Head To Black LED Head To Magenta LED Head To Cyan LED Head To Toner Sensor PCB To Reader Control PCB To Registration Sensor PCB To Fiery Control PCB To CN1 on LVPS To Rear Sensor PCB To Control Panel To HVPS To CN3 on LVPS...
Page 96 Motor Driver Board To Transfer Unit Motor To C Drum Motor To Duplex motors To Registration Shutter Solenoid To Job Offset Motor To Fuser Motor To Transfer Belt Fan To M Drum Motor To Toner Motor CM To Engine Control Board To Waste Toner Motor To Front Sensor PCB To Y Drum Motor...
Page 97 LVPS To Fuser To LVPS Fan To Power Connector on Engine Control Board To Power Connector on LED Relay PCB To Pow24 Connector on Motor Driver Board...
Page 98 Imaging Unit Sensor Board To CTG0 Connector on Engine Control Imaging Unit Fan Board Top Cover Fan Fuser Fan...
Page 99 Front Sensor Board To Registration To Temperature / Humidity To Media Thickness Clutch #1 Sensor Sensor To Connector FSNS To MPT Home on the Motor Driver Position Sensor Board To MPT Level Sensor Tray 1 Paper Sensor OHP Sensor Feed Out Sensor #1...
Page 100 Rear Sensor Board To Eject Door Close To Exit Gate Fuser Exit Sensor Sensor Solenoid Side Output Tray Stack Full Sensor Top Output Tray Stack Full Sensor Job Offset Position Sensor To Connector RSNS on the Engine Control Board...
Page 101: Feeder Board
Feeder Board To Connector TRYSNS1 on the Motor Driver Board To No Paper Sensor Feed Out Sensor #2 Registration Sensor #2 Tray 1 Side Door Detection...
Page 102 LED Relay Board To Cyan LED Head To Black LED Head To Magenta LED Head To Yellow LED Head To CN1 on the LVPS...
Page 103: Print Engine General Wiring Diagram
Print Engine General Wiring Diagram These Sensors are integrated on the Front Sensor Board...
Page 104 Print Engine General Wiring Diagram These Sensors are integrated on the Feeder Board...
Page 105 Print Engine General Wiring Diagram Right Upper Door Interlock...
Page 106 Print Engine General Wiring Diagram...
Page 107 Print Engine General Wiring Diagram...
Page 108 Print Engine General Wiring Diagram...
Page 109 Print Engine General Wiring Diagram...
Page 110 Front Sensor Board...
Page 111 Front Sensor Board...
Page 112 Feeder Board...
Page 113 Rear Sensor Board...
Page 114 Registration...
Page 115 Motor Driver Board Motor Driver Board...
Page 116 Motor Driver Board Motor Driver Board...
Page 117 Motor Driver Board Motor Driver Board...
Page 118: Led Heads
LED Heads...
Page 119 HVPS...
Page 120 LVPS...
Page 121 Fuser RFID Reader...
Page 122 Imaging Unit Sensor Board...
Page 123 Control Panel...

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Oki ES3640MFP Component Replacement Manual

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