Page 1 AR-151E CODE: 00ZAR151E/A1E DIGITAL COPIER AR-121E AR-151E MODEL ∗ This Service Manual describes only the differences from the AR-120E/150E. For the common items with the AR- 120E/150E, please refer to the AR-120E/150E manual. CONTENTS [ 1 ] GENERAL ......1 - 1 [ 2 ] CONSUMABLE PARTS .
Page 2: Major Functions
[1] GENERAL The AR-121E/151E is the SRU model of the AR-120E/150E. While the AR-120E/150E employs the drum replacement, the AR-121E/151E employs the developer replacement. Therefore, the display on the opera- tion panel is changed from “ ” (drum) to “...
Page 3: Consumable Parts
AR-151E [2] CONSUMABLE PARTS 1. Supply system table A. Europe subsidiaries/East Europe/SCA/SCNZ Name Content Life Product name Package Remark × 10 Toner CA(Black) with IC Toner AR-152LT LT=T∗10 (Toner :Net Weight 210g) × 10 Polyethylene bag × 10 250K Developer Developer AR-152LD LD=DV∗10...
Page 4: Developer Unit Installation
AR-151E 11) Attach Upper developer unit and fix it with a screw. 2. Developer unit installation 12) Rotate the MG roller gear to distribute developer evenly. 1) 2) 3) Open the side and front cabinets of the copier. 4) Remove the locking tape of the developer unit. 5) Remove the screw which is fixing the copier and Developer unit.
Page 5: Td Cartridge Replacement
AR-151E 4. TD cartridge replacement 1) Open the front and side cabinets of the copier. 2) Keep holding Toner lover, and 3) Carefully pull out Toner unit from the copier. 4) Insert Toner unit carefully into the copier. 5) Insert until the hook is engaged with the copier as shown in the fig- ure below.
Page 6: List Of Simulations
AR-151E [3] SIMULATIONS 1. List of simulations The table below shows the simulations which are not provided for the AR-120E/150E but newly added to the AR-121E/151E. Simulation 26-38 of the SR-120E/150E is deleted in the AR-121E/151E. Main code Sub code...
Page 7: User Program
AR-151E [4] USER PROGRAM The conditions of factory setting can be changed according to the use conditions. Functions which can be set with the user program Function Contents Factory setting When a certain time is passed after completion of copying, this function returns to the initial state Auto clear time automatically.
Page 8: Maintenance Table
AR-151E [5] MAINTENANCE 1. Maintenance table : Check (Clean, adjust, or replace when required.) : Clean : Replace : Adjust : Lubricate Section Parts 100K Remark Developer Developing DV blade DV side seal (F/R) Process peripheral Drum 2. Maintenance display system Life 7.2K Press and hold the density adjustment LIGHT key for more than 5 sec, and the machine will enter the...
Page 9 AR-151E COPYRIGHT © 2001 BY SHARP CORPORATION All rights reserved. Printed in Japan. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher.
Page 10 Parts marked with “ ” are important for maintaining the safety of the set. Be sure to replace these parts with specified ones for maintaining the safety and performance of the set. This document has been published to be used SHARP CORPORATION for after sales service only. The contents are subject to change without notice.
Page 11 AR-150E [1] GENERAL 1. Major functions Item SB/MB 2 Tray R-SPF without SOPM Duplex with USB with USB Model AR-120E 12CPM AR-150E 15CPM Descriptions of items CPM: Copy speed (Copies Per Minute) SB/MB: SB = Manual feed single bypass, MB = Manual feed multi bypass 2 tray: Second cassette unit.
Page 12: Copy Mode
AR-150E (1) Paper feed section of the copier [2] SPECIFICATIONS A4, B5, A5, 8.5" × 14", 8.5" × 11", 8.5" × 5.5" Paper feed size 1. Copy mode 250 sheets (56 ∼ 80g/m equivalent) (15 ∼ Paper feed A. Type capacity 21 lbs.) Type...
Page 13 AR-150E N. Additional functions S. Power consumption Max. power consumption About 1.0KWh Auto paper selection (APS) ∗ EnergyStar standard (The second level conformity) Auto magnification ratio selection Binding margin Pre-heat About 40Wh 1 set 2 copy Auto power shut off 18wh Edge erase T.
Page 14 AR-150E [3] CONSUMABLE PARTS 1. Supply system table A. Middle East, Africa Name Content Life Product name Package Remark × 1 Developer cartridge Toner/developer cartridge 7.2K AR-150DC Life setting by A4 6% (Black) (Toner 238g, Developer 190g) document <With IC> ×...
Page 15 AR-150E 2) Remove the DVF cover unit. 2. Consumable parts refill procedure • When removing, be careful not to break the two pins. [External view check points] Check for breakage of the four pins (*) and the ATC sensor connector of the DV BOX unit.
Page 16 AR-150E 5) Tilt the DV box unit and rotate the DV18T clockwise to remove 11) Face the toner supply port of the TH box unit upward, and press developer. and insert the refill hose into the toner supply port with the toner bottle kept straight up.
Page 17 AR-150E 17) Replace the IC connector. Check that there is no oil on the IC connector pins. (Do not touch with fingers.) Put a white mark on the above position. At that time, put marking for checking of the number of refilling. 18) Check the operations of the DV lever and the toner box shutter.
Page 18 AR-150E [The reattachment procedure] Remove the side sheets on the both sides of DV box unit. Clean the DV box unit with alcohol and reattach the side sheets F and R to the both sides. 0 . 5 0 . 5 DV box unit F side DV box unit R side .
Page 19 AR-150E 3) Remove the drum fixing plate and the photoconductor drum. B. Drum unit (Note) Dispose the drum fixing plate which was removed. 1) Check the external view. • Check for damage or cracks on the boss and the boss hole. •...
Page 20 AR-150E 7) Clean the cleaning section and the waste toner pipe to remove 12) Attach the drum fixing plate and the photoconductor drum. waste toner completely with a vacuum cleaner. Apply grease to the inside of the photoconductor drum. (Dia. 2) 8) Remove the felt and duplex tape completely.
Page 21 AR-150E [4] SIMULATIONS The following items are added in this model. (Not provided in the AL series.) 1. List of simulations Main code Sub code Contents Lamp ON check Operation panel display check (Maintenance lamp added) Fusing lamp ON + cooling fan high speed/low speed Copy lamp ON Maintenance counter clear...
Page 22: Parts Guide
The AR-120E/AR-150E Parts Guide describes only the parts changed from AL-1000/AL-1200 Parts Guide. For then common parts, please refer to the AL-1000/AL-1200 Parts Guide. This document has been published to be SHARP CORPORATION used for after sales service only. The contents are subject to change without...
Page 23 AR-150EP2 DEFINITION The definition of each Rank is as follows and also noted in the list A : Parts necessary to be stocked as High usage parts. B : Parts necessary to be stocked as Standard usage parts. C : Low usage parts. D : Parts necessary for refurbish.
Page 24 AR-150EP2 12 Base plate unit 2 FCP04166 10 Middle frame 16 Multi manual paper feeding cover unit 18 Multi manual paper feeding unit 19 Socket holder unit FCP04167 – 2 –...
Page 25 AR-150EP2 1 Exteriors PRICE PART PARTS CODE DESCRIPTION RANK MARK RANK T L A B H 0 1 6 7 Q S Z Z Operation instruction label (Except Russia,LAG2,LAG4,Pakistan,Philippnes) T L A B H 0 2 1 4 Q S Z Z Operation instruction label (Russian) 20 T L A B Z 0 0 5 8 Q S Z Z Class 1 label (Except Brazil,LAG2)
Page 26 AR-150EP2 10 Middle frame PRICE PART PARTS CODE DESCRIPTION RANK MARK RANK 7 N C P L - 0 0 0 6 Q S Z Z Hopper cupling 12 N F A N P 0 0 0 1 Q S Z 1 21 L F R M - 0 0 3 5 Q S Z Z Middle frame L P I N S 0 0 0 9 Q S Z Z...
Page 27 AR-150EP2 16 Multi manual paper feeding cover unit PRICE PART PARTS CODE DESCRIPTION RANK MARK RANK 3 P C O V P 0 0 2 3 Q S Z 1 Multi upper cover 6 M S P R P 0 1 1 0 Q S Z 1 Door switch spring 8 P S H E Z 0 0 7 5 Q S Z Z MB upper guide sheet...
Page 28: Packing Material & Accessories
AR-150EP2 23 Packing material & accessories PRICE PART PARTS CODE DESCRIPTION RANK MARK RANK Q A C C D 7 6 1 8 Q C Z Z AC cord (L2,Brazil,LAG2) Q A C C R 7 6 2 1 Q C Z Z AC cord (LAG4,L4) Q A C C B 7 5 2 1 Q C Z Z AC cord (South Africa)
Page 29 AR-150EP2 24 MCU PWB PRICE PART PARTS CODE DESCRIPTION RANK MARK RANK Block resistor (47 4 1/32W 42 R M P T W 4 4 7 0 Q C J J [BR123,BR124,BR125,BR126,BR131,BR132,BR133,BR135,BR138,BR140] Block resistor (47 4 1/32W 43 R M P T W 4 4 7 0 Q C J J [BR152,BR153,BR154,BR155,BR158,BR159,BR160,BR162,BR163] 44 T L A B Z 3 4 0 5 F C Z Z Version label...
Page 30: Operation Pwb
AR-150EP2 24 MCU PWB PRICE PART PARTS CODE DESCRIPTION RANK MARK RANK Resistor (1/16W 20K 116 V R S - C Y 1 J D 2 0 3 J [R225,R227,R230,R241,R242, R243,R245,R250,R254,R256] 117 V R S - C Y 1 J D 2 0 3 J Resistor (1/16W 20K [R269,R274,R275,R281,R293, R300,R341,R342] 118 V R S - C Y 1 J D 2 0 5 J...
Page 31 AR-150EP2 Index PRICE PART PARTS CODE RANK MARK RANK PHOG-1023CCZZ 23-111 PRICE PART PARTS CODE RANK MARK RANK PMLT-0026QSZZ 10- 31 PMLT-0028QSZZ 12- 27 CBOX-0002QS53 31-501 PSHEP0019QSZ1 CBOX-0002RS54 PSHEZ0045QSZ1 31-501 13- 33 CBOX-0007JS54 PSHEZ0072QSZZ 6- 30 CBOX-0007YS51 PSHEZ0074QSZZ 6- 24 CBOX-0007YS53 PSHEZ0075QSZZ CBTN-0004QS04...
Page 32 AR-150EP2 PRICE PART PRICE PART PARTS CODE PARTS CODE RANK MARK RANK RANK MARK RANK TCAUH0992FCZ1 VRS-CY1JD102J 13- 32 24-107 TCAUS0009QSZZ " 23-107 24-108 TINSE0378QSZZ VRS-CY1JD103F 24-109 TINSE0382QSZZ VRS-CY1JD103J 24-110 TINSF0380QSZZ " 24-111 TINSR0383QSZZ VRS-CY1JD105F 24-112 TINSS0381TSZZ VRS-CY1JD122J 24-113 TINSZ0379QSZZ VRS-CY1JD152J 24-114 TLABH0167QSZZ...
Page 33 AR-150E COPYRIGHT © 1999 BY SHARP CORPORATION All rights reserved. Printed in Japan. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher.
Page 34 " is important for maintaining the safety of the set. Be sure to replace these parts with specified ones for maintaining the safty and performance of the set. This document has been published to be used for SHARP CORPORATION after sales service only. The contents are subject to change without notice.
Page 35 AL-1000/1010 CAUTION This product is a class 1 laser product that complies with 21CFR 1040.10 and 1040.11 of the CDRH standard and IEC825. This means that this machine does not produce hazardous laser radiation. The use of controls, adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure.
Page 36 AL-1000/1010 At the production line, the output power Caution of the scanner unit is adjusted to 0.57 This product contains a low power laser MILLI-WATT PLUS 20 PCTS and is device. To ensure continued safety do not maintained constant by the operation of remove any cover or attempt to gain access the Automatic Power Control (APC).
Page 37 AL-1000/1010 CONTENTS Optical section ....... . . 8-3 [1] GENERAL Fusing section .
Page 38: Main Features
AL-1000/1010 [1] GENERAL 4. Environmental The environmental conditions for assuring the copy quality and 1. General the machine operations are as follows: This model is a digital personal copier produced with key words (1) Normal operating condition of “Comfort able copy, Clear copy, Easy copy” providing high copy performances and copy productivity.
Page 39: Basic Specifications
AL-1000/1010 [2] SPECIFICATIONS 1. Basic Specifications item type Desktop Copy system Dry, electrostatic Segment (class) Digital personal copier External dimensions (W × D × H) H293 × W518 × D445mm (mm) Weight Approx. 43.3lbs (19.6kg), TD and drum cartridges included 2.
Page 40 AL-1000/1010 Section, item Details Exit way Face down Paper exit section Capacity of 100 sheets output tray Original set Center Registration (left edge) Max. original B4 (10″ × 14″) size Originals Original kinds sheet, book Original size None detection Scanning system CCD sensor scanning by lighting lamp scanner CCD sensor Resolution...
Page 41: Copy Performance
AL-1000/1010 3. Copy performance Section, item Details Fixed magnification 3R + 2E (AB system : 50, 70, 81, 100, 141, 200%) ratios (Inch system : 50, 64, 78, 129, 100, 200%) Copy magnification Zooming 50 ∼ 200% (151 steps in 1% increments) magnification ratios Manual steps (manual, 5 steps...
Page 42 AL-1000/1010 4. Others Section, item Remark Can be set or canceled with user Toner save mode simulation. Additional Can be set or canceled with user Pre-heat mode function simulation. Can be set or canceled with user Auto power shut off mode simulation.
Page 43: Drum Cartridge
AL-1000/1010 [3] CONSUMABLE PARTS 1. Supply system table Common to all destinations Name Content Life Product name Package × 1 Toner/developer cartridge Develop cartridge (Black) × 1 (Toner: Net weight 220g) AL-100TD (5% document) (Developer: Net weight 190g) Drum cartirdge Drum cartridge AL-100R 2.
Page 44: External Views And Internal Structures
AL-1000/1010 [4] EXTERNAL VIEWS AND INTERNAL STRUCTURES 1. Appearance (10) (11) (12) (13) Original table Original cover Side cover Operation panel Front cover Paper tray Side cover open button Paper guides Handle (10) Paper output tray (11) Paper output tray extension (12) Power cord socket (13) Power switch...
Page 45: Operational Panel
AL-1000/1010 2. Operational panel 200% MAX. 129% 100% 100% ZOOM MIN. (10) (11) (12) (13) Exposure mode selector key Light and dark keys and ∗1 Alarm indicators and indicators exposure indicators Copy ratio selector key and Zoom indicator Copy ratio display (%) key copy ratio indicators Display ON LINE indicator...
Page 46 AL-1000/1010 3. Internal TC cartridge lock release button TD cartridge Drum cartridge Drum cartridge handle Paper feed roller Fusing unit release lever Charger cleaner Transfer charger...
Page 47: Motors And Solenoids
AL-1000/1010 4. Motors and solenoids Part name Control signal Function,operation Main motor Drives the copier. Mirror motor MRMT Drives the optical mirror base (scanner unit). Toner motor Supplies toner. Cooling fan motor Cools the optical section. Resist roller solenoid Resist roller rotation control solenoid Paper feed solenoid CPFS1 Cassette Paper feed solenoid...
Page 48: Sensors And Switches
AL-1000/1010 5. Sensors and switches Name Signal Type Function Output Mirror home position Mirror (scanner unit) MHPS Transmission sensor “H” at home position sensor home position detection POD sensor Transmissions sensor Paper exitdetection “H” at paper pass Paper transport PPD2 sensor PPD2 Transmission sensor “L”...
Page 49 AL-1000/1010 6. PWB unit Name Function Exposure lamp invertor PWB Exposure lamp (Xenon lamp) control Main PWB (MCU) Copier control Operation PWB Operation input/display Power PWB AC power input, DC voltage control, High voltage control CCD sensor PWB For image scanning LSU motor PWB For polygon motor drive TCS PWB...
Page 50: Cross Sectional View
AL-1000/1010 7. Cross sectional view (10) (11) (12) (13) (14) (15) Part name Function and operation Illuminates the original with the copy lamp and passes the reflected light to the lens unit Scanner unit (CCD). Exposure lamp Exposure lamp (Xenon lamp) Illuminates original Lens unit Scans the original image with the lens and the CCD.
Page 51: Unpacking And Installation
AL-1000/1010 subject to extreme temperature or humidity changes, e.g., [5] UNPACKING AND INSTALLATION near an air conditioner or heater. 1. A WORD ON COPIER INSTALLATION Improper installation may damage the copier. Please note the following during initial installation and whenever the copier is moved.
Page 52: Removing Protective Materials
AL-1000/1010 (2) Remove the CAUTION tape from the front cover and 3. UNPACKING remove the two protective pins from the fusing unit by pull- Unpack the copier and carry it to the installation location by ing the strings upward one at a time. holding the handles on both sides of the copier.
Page 53: Loading Copy Paper
AL-1000/1010 (7) Close the front cover and then the side cover by pressing (4) Adjust the paper guides on the paper tray to the copy paper the round projections near the side cover open button. width and length.Squeeze the lever of paper guide (A) a and slide the guide to match with the width of the paper.
Page 54: Printing Process
AL-1000/1010 [6] Printing process An OPC drum is used for the photoconductor. (Structure of the OPC drum layers) OPC layer (20microns thick) Pigment layer (0.2 to 0.3 microns thick) Aluminium drum (1) Functional diagram Main charger Laser beam Cleaning blade MG roller Drum Transfer unit...
Page 55: Outline Of Print Process
AL-1000/1010 (2) Outline of print process Semiconductor laser This printer is a non-impact printer that uses a semiconductor laser and electrostatic print process. This printer uses an OPC (Organic Photo Conductor) for its photoconductive material. First, voltage from the main corona unit charges the drum sur- face and a latent image is formed on the drum surface using a laser beam.
Page 56: Basic Function
AL-1000/1010 Step-7: Optical discharge (Semiconductor laser) Non-image area Before the drum rotation is stopped, the semiconductor laser is -600 radiated onto the drum to reduce the electrical resistance in the OPC layer and elimate residual charge, providing a uniform state to the drum surface for the next page to be printed. -400 When the electrical resistance is reduced, positive charges on Developing bias...
Page 57 AL-1000/1010 Start 1) Because the grid potential is at a low level, the drum poten- tial is at about –400V. (Carrier may not be attracted though the carrier is pulled towards the drum by the electrostatic force of –400V. 2) Developing bias ( –400V) is applied when the photoconduc- tor potential is switched from LOW to HIGH.
Page 58: Operational Descriptions
AL-1000/1010 [7] OPERATIONAL DESCRIPTIONS (1) Outline of operation The outline of operation is described referring to the basic configuration. (Basic configuration) Scanner section Operation section MCU (Main control/image process section) LSU (Laser unit) Laser diode, Polygon mirror lens Laser beam Paper exit Fusing section Process section...
Page 59: Scanner Section
AL-1000/1010 Sub scanning direction (2) Scanner section Sensor scanning area 1) How to scan documents The scanner has sensors that are arranged in a line. These sensors Main scanning scan a certain area of a document at a time and deliver outputs se- direction quentially.
Page 60: Laser Unit
AL-1000/1010 2) Laser beam path (3) Laser unit The image data sent from the MCU (image process circuit) is sent to the LSU (laser unit), where it is converted into laser beams. 1) Basic structure The LSU unit is the writing section of the digital optical system. The semiconductor laser is used as the light source, and im- ages are formed on the OPC drum by the polygon mirror and fθ...
Page 61: Fuser Section
AL-1000/1010 B. Separator pawl Fuser section Three separator pawls are used on the upper heat roller. The separator pawls are teflon coated to reduce friction with the roller and prevent a smear on the paper caused by the separator pawl. C.
Page 62: Paper Feed Section And Paper Transport Section
AL-1000/1010 Paper feed section and paper transport section 1. Paper transport path and general operations (10) (11) (12) (13) (14) (15) Scanner unit Main charger (11) Pickup roller Copy lamp Heat roller (12) Manual paper feed tray Lens unit Pressure roller (13) Manual paper feed roller LSU (Laser unit) Drum...
Page 63 AL-1000/1010 3. After about 0.1 sec from when the main motor start rotating, 6. To release the resist roller, the tray paper feed solenoid and the tray paper feed solenoid (PFS) turns on at a moment. the resist solenoid are turned on by the paper start signal to This disengages the paper feed latch from the projection of disengage the resist start latch from the clutch sleeve the clutch sleeve, transmitting rotation of the pick-up drive...
Page 64 AL-1000/1010 3. When pawl C of the manual paper feed clutch sleeve is B. Manual multi paper feed operation hung on the manual feed latch, the manual feed stopper 1. Before paper feed operation, the manual paper feed falls and the manual take-up roller rises. At that time, the solenoid (MPFS) is turned OFF as shown in the figure manual paper feed roller is rotating.
Page 65: Process Unit New Drum Detection Mechanism
AL-1000/1010 5. The solenoid turns off to close the gate and return to the in- Process unit new drum detection itial state. mechanism 1. When the power is turned on, the detection gear 38T is rotated in the arrow direction by the detection gear 20T to push the microswitch (process detection switch) installed to the machine sensor cover, making a judgement as a new drum.
Page 66: Disassembly And Assembly
AL-1000/1010 (2) Push up the lock pawls (2 positions) of the side cover, and [8] DISASSEMBLY AND ASSEMBLY remove the transfer charger. Before disassembly, be sure to disconnect the power cord for Lock pawl rear safety. The disassembly and assembly procedures are described for the following sections: 1.
Page 67 AL-1000/1010 D. Charger wire cleaning E. Charger wire replacement (1) Remove the charger cleaner from the manual paper feed (1) Remove the TC cover and remove the screw. unit. (2) Remove the spring and remove the charger wire. (3) Install a new charger wire by reversing the procedures (1) and (2).
Page 68: Operation Panel Section
AL-1000/1010 C. Assembly procedure 2. Operation panel section For assembly, reverse the disassembly procedure A. List 3. Optical section Part name Ref. page A. List Operation panel unit Operation PWB Part name Ref. page Copy lamp unit B. Disassembly procedure Copy lamp (1) Remove the screws (4 pcs.), the harness, and the opera- Lens unit...
Page 69 AL-1000/1010 (2) Remove the screws (2pcs.), and remove the copy lamp (5) Remove the screws (2 pcs.), the harness, and the optical unit from the mirror base drive wire. unit. When installing the lens unit, refer to “9-7. Lens unit installation reference.”...
Page 70: Fusing Section
AL-1000/1010 (4) Remove the screw and remove the U-turn guide. 4. Fusing section A. List Part name Ref. page Thermistor PPD2 sensor Heater lamp Pressure roller Heat roller B. Disassembly procedure (1) Remove the connectors (3 pcs.) of the rear cabinet. (2) Open the side cover, remove two screws, and remove the fusing unit.
Page 71 AL-1000/1010 (7) Remove the plate spring on the right and remove the (10) Remove the pressure release levers on the right and the heater lamp. left sides. (11) Remove the pressure roller, the pressure bearing, and the pring. Hearter lamp Note: Apply grease to the sections specified with (8) Remove the spring and remove the separation pawls (3 Pressure roller...
Page 72: Tray Paper Feed/Transport Section
AL-1000/1010 (6) Remove the C-ring and the fusing bearing, and remove the 5. Tray paper feed/transport section heat roller. A. List Part name Ref. page PPD1 sensor PWB 8-11 Heat roller LSU unit 8-10 Intermediate frame unit 8-10 Paper feed roller 8-11 B.
Page 73 AL-1000/1010 (3) Remove two screws and remove the toner motor. (5) Remove the pulleys on the both sides and remove the paper exit roller. (4) Remove two springs and open the intermediate frame unit. (6) Pull out the paper exit roller knob and remove the belt.
Page 74 AL-1000/1010 (7) Release the belt pulley (a) lock and remove the belt pulley (9) Remove the harness guide. bearing. (10) Remove five screws and remove the main drive plate and the belt. (8) Remove the paper exit roller. CAUTION:Attach the gears securely...
Page 75 AL-1000/1010 (11) Remove the parts as shown below, and remove the pres- (13) Remove two screws and remove the fusing connector. sure release solenoid and the paper feed solenoid. (14) Remove five screws and the connector, and lift the inter- mediate frame unit to remove.
Page 76 AL-1000/1010 (17) Remove three screws and remove the TC front paper (19) Remove two E-rings and remove the paper feed roller. guide. (20) Remove three E-rings and remove the clutch unit. Back Clutch unit Paper feed roller Front (18) Remove the screw and the connector, and remove the PPD1 sensor PWB.
Page 77: Manual Paper Feed Section
AL-1000/1010 (2) Remove the screw and remove the side door detection 6. Manual paper feed section unit. A. List Part name Ref. page Manual transport roller 8-15 Cassette detection switch 8-13 PPD1 sensor PWB 8-13 Side door detection unit 8-12 B.
Page 78 AL-1000/1010 (4) Remove the PPD1 sensor PWB. (6) Remove the cassette detection switch. Wire treatment Wire treatment (5) Remove the E-ring and remove the manual paper feed transport roller. (7) Remove the multi cover. Multi cover 8-13...
Page 79 AL-1000/1010 (3) Remove three screws and remove the multi paper feed Multi unit upper frame. (1) Remove the screw and remove the multi upper cover. (4) Remove two screws and remove the multi feed bracket unit from the multi paper feed upper frame. (2) Remove the screw and remove the side door detection unit.
Page 80 AL-1000/1010 (5) Remove three E-rings and remove the manual paper feed (7) Cut the binding band and remove the multi paper feed roller B9. solenoid. Multi paper feed solnoid (6) Remove the pick-up roller. C. Assembly procedure For assembly, reverse the disassembly procedure. D.
Page 81: Rear Frame Section
AL-1000/1010 (3) Remove two screws and one harness, and remove the 7. Rear frame section main motor. A. List Part name Ref. page Mirror motor 8-16 Main motor 8-16 Exhaust fan motor 8-16 B. Disassembly procedure (1) Remove three screws and remove the rear cabinet. (4) Remove two screws and one connector, and remove the exhaust fan motor.
Page 82: Power Section
AL-1000/1010 C. Assembly procedure 8. Power section For assembly, reverse the disassembly procedure. A. List Part name Ref. page Power PWB 8-17 B. Disassembly procedure (1) Remove two screws and one connector, and remove the power PWB. 8-17...
Page 83 AL-1000/1010 IV. Adjustment procedure [9] Adjustment 1) Remove the right cabinet (manual paper feed unit), the 1. Optical section document reference plate. (1) Image distortion adjustment 2) Remove the document glass. There are following two types of image distortion. Horizontal image distortion Vertical image distortion In this machine, the image distortion is adjusted by changing the parallelism of mirrors (copy lamp unit, No.
Page 84 AL-1000/1010 7) Manually turn the copy lamp unit/No.2/3 mirror unit drive gear to bring No.2/3 mirror unit into contact with the positioning plate, and perform the procedure of step 4). Repeat procedures of steps 4) to 7) until the parallelism of No.2/3 mirror unit is properly set.
Page 85 AL-1000/1010 10) Check the horizontal image distortion. b. Vertical image distortion adjustment If LL = LR, there is no horizontal distortion I. Summary In this adjustment, the left and right balance is adjusted by LL and LR: Distance between the copy changing the left and right balance of the No.
Page 86 AL-1000/1010 3) If the right-left distortion balance is improper, loosen the a. Outline fixing screw of No.2/3 mirror unit rail to change and ad- The main scanning (front/rear) direction magnification ratio just the right-left balance of No.2/3 mirror unit rail. adjustment is made automatically or manually.
Page 87 AL-1000/1010 2) Set the copy magnification ratio to 100%. 5) Calculate the main scanning direction magnification ratio. Main scanning direction magnification ratio ⁄ ″ × 11″ paper. 3) Make a copy on A4 or 8 Copy image dimensions × 100 (%) 4) Measure the length of the copied scale image.
Page 88 AL-1000/1010 Original (Scale) HARDDENCD STAINLESS JAPAN 1/2mm Shizuoka Paper feed HARDDENCD direction STAINLESS JAPAN 1/2mm Shizuoka Comparison point Reference Copy 4) Measure the length of the copied scale image. (3) Lens unit attachment reference Attach the lens unit so that the lens unit number on the lens ad- 5) Calculate the sub scanning direction copy magnification justment plate is aligned with the scribe line on the base plate.
Page 89 AL-1000/1010 4) Measure the image loss amount (R mm) of the scale image. (4) Image position adjustment Set C = 10 × R (mm). (Example: Set the value of C to 30.) There are following five kinds of image position adjustments, When the value of C is increased by 10, the image loss is which are made by laser control except for the image scan start decreased by 1mm.
Page 90: Copy Density Adjustment
AL-1000/1010 4) If the measurement value is out of the specified range, 2. Copy density adjustment change the set value and repeat the adjustment procedure. (1) Copy density adjustment timing The default value is 50. The copy density adjustment must be performed in the follow- ing cases: 3.
Page 91: Test Chart
“4” is slightly mode lamp ON copied. (3) Make a copy. Check the adjustment level (shown in the above table) of the exposure test chart (Sharp Gray Scale). Test chart Sharp Gray Scale adjustment level Non toner save mode Slightly copied.
Page 92: High Voltage Adjustment
AL-1000/1010 (2) DV bias adjustment 3. High voltage adjustment Note: (1) Main charger (Grid bias) A digital multi meter with internal resistance of 1GΩ Note: must be use for correct adjustment. Use a digital multi meter with internal resistance of 10MΩ...
Page 93: Simulation , Trouble Codes
AL-1000/1010 [10] SIMULATION , TROUBLE CODES 1.Entering the simulation mode To enter the serviceman simulation mode, press the keys as follows: Clear → Density select → Clear → Density select To cancel the simulation mode, press the clear key. Flow chart o entering the simulation mode Start Is there a sub Press the COPY key.
Page 94: List Of Simulation
AL-1000/1010 2. List of simulation Main code Sub code Content Scanner unit operation check Operation panel display lamps operation check Fusing lamp and cooling fan operation check Copy lamp operation check Paper feed solenoids (CPFS1, CPFS2, MPFS) operation check Resist solenoid (RRS) operation check Warm-up time display and aging with JAM Intermittent aging Developing bias check...
Page 95: Contents Of Simulations
AL-1000/1010 3. Contents of simulations Main code Sub code Contents Scanner unit operation check (Operation/Procedure) 1. When this simulation is executed, the mirror home position is detected. Sensor name display lamp Mirror home position sensor OPC drum cartridge replacement lamp 2, When the _START key is pressed, scanning is executed at the speed corresponding to the currently set copy magnification ratio.
Page 96 AL-1000/1010 Main code Sub code Contents Developing bias check (Operation/Procedure) When the START key is pressed, the developing bias is outputted for 30 sec. Main charger (Grid high output mode) check (Operation/Procedure) When the START key is pressed, the main charger output is supplied for 30 sec in the grid voltage HIGH mode. Grid voltage (Grid low output mode) check (Operation/Procedure) When the START key is pressed, the main charger output is supplied for 30 sec in the grid voltage LOW mode.
Page 97 AL-1000/1010 Main code Sub code Contents Drum counter clear (Operation/Procedure) When the START key is pressed, the drum counter value is reset to 0. Scanner counter clear (Operation/Procedure) When the START key is pressed, the scanner counter value is reset to 0. Main motor operation check (Operation/Procedure) When the START key is pressed, the main motor is rotated for 30 sec.
Page 98 AL-1000/1010 Main code Main code Contents Rear edge void setting (Operation/Procedure) 1. When this simulation is executed, the currently set code number of rear edge void setting is displayed. 2. Enter the code number of rear edge void setting and press the START key, and the setting will be changed. Code number Rear edge void setting Rear edge void allowed...
Page 99 AL-1000/1010 Main code Main code Main code Paper sensor status display (Operation/Procedure) The paper sensor status is displayed on the copy quantity display. Sensor name Display lamp Resist front paper sensor(PPD1) Developing lamp replacement lamp Fusing section paper sensor (PPD2) JAM lamp Paper exit sensor (PDD) OPC drum cartridge replacement lamp...
Page 100 AL-1000/1010 Main code Main code Main code Relationship between the displayed values and the GAMMA ADJUST register Exp1 Exp2 Exp3 Exp4 Exp5 TEXT PHOTO The value displayed after execution of this simulation can be set in the range of 0 - 99 with 50 as the center value. When the text mode set value is Gat3, for example, the GAMMA ADJUST register value set at Exp1 is: Text Exp1 = Gat3 - 50 - 24 When 40 is set to Gat3, Text Exp1 = 40 - 50 - 24 = -34...
Page 101 AL-1000/1010 Main code Sub code Contents Lead edge position and paper lead edge/rear edge void adjustment Used to adjust the copy image position on copy paper and the lead edge/rear edge void amounts. Performed by adjusting the scanning start position and print start position (resist roller ON timing) in 100%. (Operation/Procedure) 1.
Page 102 AL-1000/1010 Main code Sub code Contents * Machine with the multi manual paper feed unit installed Adjustment mode Lamps ON Main cassette paper feed AE, main cassette lamp 2nd cassette paper feed AE, 2nd cassette lamp Manual paper feed AE, manual feed lamp SPF/Resist AE, TEXT, PHOTO lamp * Machine with the single manual paper feed unit installed...
Page 103: Trouble Codes
AL-1000/1010 4. Trouble Codes Main code Sub code Trouble content Detail of trouble HSYNC cannot be LSU (laser diode, reception element, APC circuit) trouble detected. LSU drive circuit (ASIC) trouble CCD drive circuit (CCD PWB, ASIC harness) trouble CCD white level trouble Copy lamp lighting trouble (Copy lamp, invertor PWB) CD black level trouble CCD drive circuit (CCD PWB, ASIC, harness) trouble...
Page 104: Change The Setting
AL-1000/1010 [11] USER PROGRAM The conditions of factory setting can be changed according to the use conditions. Functions which can be set with the user program Function Contents Factory setting When a certain time is passed after completion of copying, this function returns to the Auto clear.
Page 105: Electrical Section
AL-1000/1010 [12] ELECTRICAL SECTION 1. Block diagram A. Overall block diagram MCU PWB JITTER SRAM Toner Motor SYNC IC Reference ASIC Printed LASER Visual Data UART Other Loads Other Inputs MHPS DVSEL MIRROR MOTOR MAIN PPD1 PPD2 MOTOR MMLD MHPS CED1 CPFS1 INTERLOCK SWITCH...
Page 106 AL-1000/1010 B. Main PWB block diagram (Load drive block diagram) 12-2...
Page 107: Circuit Descriptions
AL-1000/1010 2. Circuit descriptions A. Maiin PWB (MCU) (1) CPU signal table CPU pin table Model without SPF PIN No Signal code Input/output Operating /CS1 Output Chip Select for SRAM /CS0 Output Chip Select for EPROM D-GND D-GND Output Address Bus (NC-pull up) Output Address Bus Output...
Page 108 AL-1000/1010 PIN No Signal code Input/output Operating Data input/output Data Bus Data input/output Data Bus Data input/output Data Bus Data input/output Data Bus Data input/output Data Bus Data input/output Data Bus Data input/output Data Bus Data input/output Data Bus D-GND Data input/output Data Bus Data input/output...
Page 109 AL-1000/1010 PIN No Signal code Input/output Operating SELIN3 Output Input select 3 SELIN2 Output Input select 2 SELIN1 Output Input select 1 Output Power relay control PR Output Resist roller solenoid RPC D-GND D-GND SCLK Output Clock Line for EEPROM Output Data Line for EEPROM Analog Reference Voltage-A5V...
Page 110 AL-1000/1010 (2) ASIC 1. Outline Fig. 4 shows the block diagram of the ASIC. The ASIC is composed of the following three blocks; the image process section, the print control section, and the I/F section. The image process section processes the image data from the CCD PWB according to the operation mode, such as shading, AE process, resolution conversion.
Page 111 AL-1000/1010 2. ASIC input/output PIN No. Signal name IN/OUT Connected to Description /SCANSP CPU (I/O) Scanner process interrupt signal /PRSTART Print start trigger signal TMON Toner motor ON/OFF TMCLK Toner motor reference clock 3.3v Power CPUAD7 CPU address bus CPUAD6 CPU address bus Power CPUAD5...
Page 112 AL-1000/1010 PIN No. Signal name IN/OUT Connected to Description MAD2 DRAM Address bus of DRAM (page memory) MAD3 DRAM Address bus of DRAM (page memory) MAD4 DRAM Address bus of DRAM (page memory) MAD5 DRAM Address bus of DRAM (page memory) MAD6 DRAM Address bus of DRAM (page memory)
Page 113 AL-1000/1010 PIN No. Signal name IN/OUT Connected to Description Electronic sort /ESPRD (Not used) board Power Electronic sort /ESREQ (Not used) board Electronic sort /ESACK (Not used) board Electronic sort /ESCS (Not used) board PARAD0 IN/OUT 1284CN board (Not used) PARAD1 IN/OUT 1284CN board...
Page 114 AL-1000/1010 PIN No. Signal name IN/OUT Connected to Description Power SRAM SD17 IN/OUT Data line to SRAM before are separation (separation) SRAM SOE1 Read enable line to SRAM before area separation (separation) SRAM SWE1 Write enable line to SRAM before area separation (separation) SRAM SCS1...
Page 115 AL-1000/1010 PIN No. Signal name IN/OUT Connected to Description SRAM SAD10 Address line to SRAM before area separation (separation) SRAM SAD11 Address line to SRAM before area separation (separation) SRAM SAD12 Address line to SRAM before area separation (separation) SRAM SAD13 Address line to SRAM before area separation (separation)
Page 116 AL-1000/1010 PIN No. Signal name IN/OUT Connected to Description PORTOUT20 (Not used) OP-LATCH Tr array IC Latch signal for operation circuit. Data latch at LOW. MRPS2 Tr array IC Mirror speed control signal. Mirror speed 2 at LOW. MRPS1 Tr array IC Mirror speed control signal.
Page 117: Reset Circuit
AL-1000/1010 PIN No. Signal name IN/OUT Connected to Description /CPUWR CPU write signal /CPURD CPU read signal Power CPUCLK CPU system clock Power TEST AUTO SCAN High: Normal Low: Test PORT1 TEST /SCANST CPU (I/O) Scanner process start signal (3) Reset circuit This circuit detects ON/OFF of power to control start/stop of each circuit.
Page 118 AL-1000/1010 (4) Heater lamp control circuit (1) Outline The heater lamp control circuit detects the heat roller surface temperature and converts in into a voltage level, which is in- putted to the CPU analog input pin. The CPU converts the analog voltage into a digital signal level and compares it with the set value of the simulation to turn on/off the heater lamp according to the level, maintaining the heat roller surface temperature at a constant level.
Page 119: Main Motor Drive Circuit
AL-1000/1010 The lower the heat roller surface temperature is, the greater the (6) Toner supply motor drive circuit thermistor resistance is, and vise versa. The IC101 is the motor control IC, which generates the pseudo Therefore, the lower the heat roller surface temperature is, the AC waveform with the pulse signals (TM, TM-) outputted from higher the thermistor terminal voltage is, and vise versa.
Page 120: Mirror Motor Circuit
AL-1000/1010 (8) Mirror motor circuit The mirror motor is a stepping motor, and it uses the IC118 and the constant current chopper control IC (SLA7027). For control, the CPU outputs the drive signal to the IC118 to drive the mirror motor with 1-2 phase excitement. 12-16...
Page 121 AL-1000/1010 (9) Power circuit block diagram Block diagram The power circuit is composed of the main section, the high voltage circuit, the FW signal section, and the heater lamp drive circuit. The main section directly rectifies the AC power current and switch-converts with the DC/DC convertor, and rectifies again and smoothes to form each DC power.
Page 122 AL-1000/1010 Circuit descriptions (1) Main section a. Noise filter circuit The noise filter circuit of the DC power is composed of L and C as shown in the figure below. It reduces normal mode noises and common mode noises which come from and go to the AC line.
Page 123: Heater Lamp Drive Circuit
AL-1000/1010 (2) FW signal The AC input voltage is full-wave rectified by D5 and D6. When the voltage is divided by resistors R18, R19, and R27 and decreased below 2.5V, the shunt regulator IC7 is turned OFF to turn OFF photo coupler PC3, and turn ON transistor Q3.
Page 124 AL-1000/1010 (10) Cl invertor PWB (circuit) CL (Xenon lamp) CL- (CNT) Invertor circuit and transformer Output 1.5kV (effective voltage) Input +24V Circuit description The Two transistors connected in series to the transformer are switched on/off by the control signal (CL-) from the MCU. By this switching operation, the signals are converted into switching pulses and a high frequency power is supplied to the CL (Xenon lamp) by the transformer.
Page 125: Operation Section
AL-1000/1010 The amplified CCD signal output is sent to the clamp circuit. In the clamp circuit, the black level is clamped to 2V at the BCLK signal timing by the analog switch. The clamped voltage is maintained for one line by the coupling capacitor. The clamped analog signal is impedance-converted and inputted to the AD convertor.
Page 126: Circuit Diagram
AL-1000/1010 [13] CIRCUIT DIAGRAM 13-1...
Page 127 AL-1000/1010 13-2...
Page 128 AL-1000/1010 13-3...
Page 129 AL-1000/1010 13-4...
Page 130 AL-1000/1010 13-5...
Page 131 AL-1000/1010 13-6...
Page 132 AL-1000/1010 13-7...
Page 133 AL-1000/1010 13-8...
Page 134 POWER SUPPLY (100V/110V)
Page 135 POWER SUPPLY (120V/127V)
Page 136 POWER SUPPLY (200V Series)
Page 137 ACTUAL WIRING DIAGRAM...
Page 138 AL-1000/1010 COPYRIGHT©1998 BY SHARP CORPORATION All rights reserved. Printed in Japan. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher.

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