Oki ES3640 MFP Parts list manual

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. 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