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Sharp AL-1215 Service Manual

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(AL-1551CS)
[ 1 ] GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
[ 2 ] SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
[ 3 ] CONSUMABLE PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
[ 4 ] EXTERNAL VIEWS AND INTERNAL STRUCTURES . . . . . . . . . 4 - 1
[ 5 ] UNPACKING AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
[ 6 ] COPY PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1
[ 7 ] OPERATIONAL DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
[ 8 ] DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1
[ 9 ] ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 1
[10] SIMULATION, TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . 10 - 1
[11] USER PROGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 1
[12] ELECTRICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 1
[13] CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 1
Parts marked with "
" are important for maintaining the safety of the machine. Be sure to replace these parts
with the replacement parts specified to maintain the safety and performance of the machine.
SERVICE MANUAL
DIGITAL LASER COPIER/
DIGITAL MULTIFUNCTIONAL
SYSTEM
MODEL
CONTENTS
SHARP CORPORATION
CODE : 00ZAL1551CS1E
AL-1215
AL-1530CS
AL-1540CS
AL-1551CS
This document has been published to be used
for after sales service only.
The contents are subject to change without notice.

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  Summary of Contents for Sharp AL-1215

  • Page 1 SERVICE MANUAL CODE : 00ZAL1551CS1E DIGITAL LASER COPIER/ DIGITAL MULTIFUNCTIONAL SYSTEM AL-1215 AL-1530CS AL-1540CS (AL-1551CS) AL-1551CS MODEL CONTENTS [ 1 ] GENERAL ......... . . 1 - 1 [ 2 ] SPECIFICATIONS.
  • Page 2 CAUTION This product is a class 1 laser product that complies with 21CFR 1040 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 3 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 4: Table Of Contents

    CONTENTS GENERAL OPERATIONAL DESCRIPTIONS 1. Major functions........1-1 1.
  • Page 5: General

    Item Color SB/MB 2 Tray R-SPF SOPM Duplex Memory Scanner printer printer Model AL-1215 12CPM AL-1530CS 13CPM AL-1540CS 14CPM AL-1551CS 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 6: Specifications

    [2] SPECIFICATIONS 1. Basic Specifications Item Type Desktop Copy system Dry, electrostatic Segment (class) Digital personal copier Copier dimensions AL-1215 20.4"(W)X18.2"(D)X11.6"(H) (518mm(W)X462.5mm(D)X295.6mm(H)) AL-1530CS 20.4"(W)X18.2"(D)X11.6"(H) (518mm(W)X462.5mm(D)X295.6mm(H)) AL-1540CS 20.4"(W)X19.4"(D)X15.0"(H) (518mm(W)X492.5mm(D)X380.4mm(H)) AL-1551CS 20.4"(W)X19.4"(D)X18.3"(H) (518mm(W)X492.5mm(D)X465.4mm(H)) Weight AL-1215 35.3lbs.(17Kg) TD and drum cartridges included (Approximately) AL-1530CS 35.3lbs.(17Kg)
  • Page 7 Power source Voltage 100V, 110V, 120/127V, 230V, 240V Frequency Common use for 50 and 60Hz Power consumption Max. Less than 1000W Average AL-1215 300 Wh/H *1) (during copying) AL-1530CS 300 Wh/H *1) AL-1540CS 300 Wh/H *1) AL-1551CS 310 Wh/H *1)
  • Page 8: Copy Performance

    3. Copy performance Section, item Details AL-1215 AL-1530CS AL-1540CS AL-1551CS Copy magnification Fixed 3 Reduction + 2 Enlargement magnification (AB system : 25, 70, 86, 100, 141, 400%) ratios (Inch system : 25, 64, 78, 100, 129, 400%) Zooming 25 - 400%...
  • Page 9: Gdi Printer

    4. GDI Printer Print speed Max. 12ppm (A4, 8.5" x 11") (Mono CW chart / Pentium III 733Mhz / 128MB / Win 98) First print time 9.6 sec. (without data transfer time) Duplex None Memory 8MB (Duplex model: 16MB) Interface IEEE1284 / USB 1.1 Emulation Resolution...
  • Page 10: Consumable Parts

    [3] CONSUMABLE PARTS 1. Supply system table Common to all destinations Name Content Life Product name Package Develop cartridge (Black) x 1 Toner/developer cartridge x 1 AL-100TD (Except Europe) (Toner: Net weight 220g)(Developer: Net weight 190g) (5% document) Develop cartridge (Black) x 1 Toner/developer cartridge x 1 AL-110TD (Except Europe)
  • Page 11: Production Control Number(Lot No.) Identification

    3. Production control number(lot No.) identification <Developing cartridge> Production month Production day Destination code (Dealer, distributor, OEM, etc.) Production place (SOCC: Fixed to B.) End digit of year Version No. Production control label attachment position Destination Division EX Destination A same pack B same pack Option Destination <Drum cartridge>...
  • Page 12: External Views And Internal Structures

    [4] EXTERNAL VIEWS AND INTERNAL STRUCTURES 1. Appearance SPF/RSPF Interface Single bypass Original cover Side cover Bypass tray Bypass tray guides Side cover open button Front cover Paper tray Operation panel Original table 10 Document feeder tray SPF exit area *1 / RSPF exit area *2 12 Original guides 13 Feeding roller cover USB interface...
  • Page 13: Operation Panel

    3. Operation panel 13 14 (AL-1551CS) Duplex Mode select key and indicator Exposure mode selector key and indicators (RSPF only) Use to sequentially select the exposure modes: AUTO, MANUAL or PHOTO. Selected mode is shown by a lit indicator. Light and dark keys and exposure indicators Alarm indicators Use to adjust the MANUAL or PHOTO exposure level.
  • Page 14 ON LINE indicator The ON LINE key is pressed and on line and off line are changed. Indicates the unit is ready for printing or scanning is being performed. (On line) Blinking: Printing or data is being received from a computer. Off: Copying is being performed.
  • Page 15: Motors And Solenoids

    4. Motors and solenoids Part name Control signal Function / Operation Main motor Drives the copier. Scanner 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...
  • Page 16: Sensors And Switches

    5. Sensors and switches Name Signal Type Function Output Scanner unit home position MHPS Transmission sensor Scanner unit home position detection "H" at home position sensor POD sensor Transmission sensor Paper exit detection "H" at paper pass PPD2 sensor PPD2 Transmission sensor Paper transport detection 2 "L"...
  • Page 17: Pwb Unit

    6. PWB unit Name Function Exposure lamp invertor PWB Exposure lamp (CCFL) 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 For toner sensor control...
  • Page 18: Cross Sectional View

    7. Cross sectional view Part name Function and operation Scanner unit Illuminates the original with the copy lamp and passes the reflected light to the lens unit(CCD). Exposure lamp Exposure lamp (CCFL) Illuminates original LSU (Laser unit) Converts the original image signal into laser beams and writes onto the drum. Paper exit roller Roller for paper exit Main charger...
  • Page 19: Unpacking And Installation

    [5] UNPACKING AND INSTALLATION 2. Cautions on handling Be careful in handling the copier as follows to maintain the perfor- 1. Copier installation mance of this copier. Do not drop the copier, subject it to shock or strike it against any Improper installation may damage the copier.
  • Page 20: Unpacking

    1) Remove pieces of tape and protective cover. Then open the origi- nal cover and remove protective materials (a) and (b). AL-1215/AL-1530CS AL-1215/AL-1530CS 2) Remove the CAUTION tape from the front cover and remove the two protective pins from the fusing unit by pulling the strings upward one at a time.
  • Page 21: Loading Copy Paper

    5) Hold the tab of the protective cover and pull the tab to remove the cover. Paper Paper guide (A) guide (B) 6) Gently insert the TD cartridge until it locks in place. 5) Fan the copy paper and insert it into the tray. Make sure the edges go under the corner hooks.
  • Page 22 (Hardware and software requirements) (Flow of installation) Check the following hardware and software requirements in order to Refer to the following table and then begin installation install the software. Operating Interface Reference pages for how to install Computer type IBM PC/AT or compatible computer equipped with system a USB1.1 or bi-directional parallel interface...
  • Page 23 11) Begin installation of the scanner driver. 4. When the "The MFP driver installation is complete." dialog box 1. "SHARP AL-xxxx" (where xxxx is the model name of your appears, click the "OK" button. MFP) will appear in the "Found New Hardware Wizard" dialog box.
  • Page 24 12) Begin installation of the printer driver. 1. "SHARP AL-xxxx" (where xxxx is the model name of your MFP) will appear in the "Found New Hardware Wizard" dialog box. Select "Install the software automatically (Recom- mended)" and click the "Next" button.
  • Page 25 6) Check the contents of the package on the screen, and then click the "Start" button. The software packages to be installed will be displayed on the screen. If inappropriate packages are displayed, click the "Back" button to select only appropriate software packages. 7) Copying files for MFP driver installation and parallel interface setup (This step will start if it was selected in step 4).
  • Page 26: Connecting The Interface Cable

    4. When the "Select Program Folder" window appears, click the Connecting the parallel interface cable "Next" button. 1) Obtain an IEEE1284 shielded parallel interface cable. The setup program will start to copy the files. 2) Ensure that your computer and unit are turned off. If the dialog box asking "If you have TIFF files saved using 3) Insert the cable into the parallel interface connector located on the Photo-Shop or Imaging for Windows you should hit Skip"...
  • Page 27: Usb Interface

    12. USB interface Connector 4-pin ACON UBR23-4K2200 Type-B connector Cable Shielded twisted pair cable (2 m (6 feet) Max.: high-speed transmission equivalent) Pin configuration The pin numbers and signal names are listed in the following table. Pin No. Signal name -DATA +DATA 13.
  • Page 28: Copy Process

    [6] COPY PROCESS An OPC drum is used for the photoconductor. (Structure of the OPC drum layers) OPC layer (20 microns thick) Pigment layer (0.2 to 0.3 microns thick) Aluminum drum 1. Functional diagram Main charger Laser beam Cleaning blade MG roller Drum Transfer unit...
  • Page 29: Outline Of Print Process

    2. Outline of print process Step-2: Exposure (laser beam, lens) A Laser beam is generated from the semiconductor laser and This printer is a non-impact printer that uses a semiconductor laser controlled by the print pattern signal. The laser writes onto the OPC and electrostatic print process.
  • Page 30 Step-3: Developing (DC bias) Step-4: Transfer A bias potential is applied to the MG roller in the two component The visible image on the drum surface is transferred onto the print paper by applying a positive charge from the transfer corona to the magnetic brush developing method, and the toner is charged negative through friction with the carrier.
  • Page 31 Start Step-7: Optical discharge (Semiconductor laser) Before the drum rotation is stopped, the semiconductor laser is 1) Because the grid potential is at a low level, the drum potential is at radiated onto the drum to reduce the electrical resistance in the OPC about -400V.
  • Page 32: Operational Descriptions

    [7] OPERATIONAL DESCRIPTIONS 1. Outline of operation The outline of operation is described referring to the basic configuration. (Basic configuration) Scanner section Operation section Printer/ MCU (Main control/image process section) Scanner I/F USB or Parallel Note: The scanner function is effective only by USB connection.
  • Page 33: Scanner Section

    2. Scanner section A. Scanner unit The scanner unit in the digital copier scans images. It is composed of the optical unit and the drive unit. The optical unit performs scanning in the main scan direction with the light receiving elements (color CCD).
  • Page 34: Laser Unit

    3. Laser unit B. Laser beam path The image data sent from the MCU (image process circuit) is sent to the LSU (laser unit), where it is converted into laser beams. A. Basic structure The LSU unit is the writing section of the digital optical system. The semiconductor laser is used as the light source, and images are formed on the OPC drum by the polygon mirror and fθ...
  • Page 35: Paper Feed Section And Paper Transport Section

    A. General description 2) The surface temperature of the upper heat roller is set to 165 - 190°C. The surface temperature during the power save mode is General block diagram (cross section) set to 100°C. Thermal fuse Separator pawl 3) The self-check function comes active when one of the following malfunctions occurs, and an "H"...
  • Page 36 (1) Cassette paper feed operation 5) At this time, the paper is fed passed the paper entry detection switch (PPD1), and detected by it. After about 0.15 sec from 1) The figure below shows the positions of the pick-up roller, the detection of paper by PPD1, the tray paper feed solenoid (PFS) paper feed clutch sleeve, and the paper feed latch in the initial turns on so that the clutch sleeve projection comes into contact...
  • Page 37 (2) Manual multi paper feed operation 3) When pawl C of the manual paper feed clutch sleeve is engaged with the manual feed latch, the manual feed stopper falls and the 1) Before paper feed operation, the manual paper feed solenoid manual take-up roller rises.
  • Page 38: Process Unit New Drum Detection Mechanism

    (3) Conditions of occurrence of paper misfeed 2) When the detection gear 38T turns one rotation, there is no gear any more and it stops. a. When the power is turned on: The latch section of the 38T gear is latched and fixed with the PPD or POD is ON when the power is turned on.
  • Page 39: Document Transport (Duplex Model)

    8. D-D (Duplex to Duplex) mode paper/ C. Operational descriptions document transport (Duplex model) Time chart (Tray feed) Document set A. Initial state SPID ON Document set sensor Set duplex documents on the document tray. Set paper on the cassette. (In the duplex mode, the manual feed tray Document feed unit lamp ON cannot be selected.) Copy start...
  • Page 40 C. Back copy Document transport: By switchback operation, the document is sent through the PS roller to the exposure section, where the back of the document is exposed. • It is sent to the document exit section by the transport roller and the paper exit roller.
  • Page 41: Disassembly And Assembly

    [8] DISASSEMBLY AND ASSEMBLY 2) Push up the lock pawls (2 positions) of the side cover, and remove the transfer charger. Before disassembly, be sure to disconnect the power cord for Lock pawl rear safety. 1. Do not disconnect or connect the connector and the harness during the machine is powered.
  • Page 42: Operation Panel Section

    2. Operation panel section 2) Set the charger cleaner to the transfer unit, and move it recipro- cally a few times in the direction of the arrow shown in the figure A. List below. Part name Ref. Operation panel unit Operation PWB B.
  • Page 43: Optical Section

    3) Remove four screws, and remove the operation cabinet. 2) Remove the connector and the clamp, and remove the RSPF unit. 4) Remove four screws, and remove the operation PWB. Note that there are 10 pawls 3) Remove the four screws, remove the operation unit, and discon- nect the connector.
  • Page 44 8) Move the carriage to the position indicated on the figure. C. Assembly procedure 9) Loosen the screw which is fixing the tension plate. CCD core 10) Move the tension plate in the arrow direction to release the ten- 1) Pass the core through the CCD-MCU harness. sion, and remove the belt.
  • Page 45: Fusing Section

    4. Fusing section 4) Remove the screw and remove the U-turn guide. A. List Part name Ref. 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 46 7) Remove the plate spring on the right and remove the heater lamp. 10) Remove the pressure release levers on the right and the left sides. 11) Remove the pressure roller, the pressure bearing, and the spring. Note: Apply grease to the sections specified with an asterisk (*). Heater lamp Pressure roller 8) Remove the spring and remove the separation pawls (3 pcs.).
  • Page 47: Tray Paper Feed/Transport Section

    5. Tray paper feed/transport section 6) Remove the C-ring and the fusing bearing, and remove the heat roller. A. List Part name Ref. Heat roller PPD1 sensor PWB LSU unit Intermediate frame unit Paper feed roller B. Disassembly procedure 1) Remove two screws, and remove the hinge guide R. 2) Disconnect three positions of the connectors.
  • Page 48 5) Remove the PWB insulation mylar and remove the paper transport 7) Remove two springs and open the intermediate frame unit. detection sensor (PPD2). 6) Remove two screws and remove the toner motor. 8) Remove the pulleys on the both sides and remove the paper exit roller.
  • Page 49 9) Pull out the paper exit roller knob and remove the belt. 11) Remove the paper exit roller. 12) Remove the harness guide. 10) Release the belt pulley (a) lock and remove the belt pulley bearing. AL-1551CS DISASSEMBLY AND ASSEMBLY 8 - 9...
  • Page 50 13) Remove five screws and remove the main drive plate and the belt. 15) Remove six screws and remove the LSU unit. The scan inclination classification is indicated on the right or the left of the LSU production number label according to the classifica- tion.
  • Page 51 Addition of the spacer [Note for assembling the LSU] Scan inclination classification 1: Add the LSU spacer to the rear When installing the LSU, turn the LSU clockwise and fix with side of the machine. screws in order to provide an attachment backlash in the proper direction.
  • Page 52 17) Remove two screws and remove the fusing connector. 21) Remove three screws and remove the TC front paper guide. 18) Remove five screws and the connector, and lift the intermediate frame unit to remove. 22) Remove the screw and the connector, and remove the PPD1 sen- sor PWB.
  • Page 53: Manual Paper Feed Section

    23) Remove two E-rings and remove the paper feed roller. B. Disassembly procedure 24) Remove three E-rings and remove the clutch unit. Single unit 1) Remove the screw and remove the single upper cover. Back Clutch unit Paper feed roller Front 2) Remove the screw and remove the side door detection unit.
  • Page 54 3) Remove three screws and remove the single manual feed upper 5) Remove the E-ring and remove the manual paper feed transport frame. roller. 6) Remove the cassette detection switch. 4) Remove the PPD1 sensor PWB. Wire treatment Wire treatment AL-1551CS DISASSEMBLY AND ASSEMBLY 8 - 14...
  • Page 55 7) Remove the multi cover. 2) Remove the screw and remove the side door detection unit. Multi cover Back Wire treatment 3) Remove three screws and remove the multi paper feed upper Multi unit frame. 1) Remove the screw and remove the multi upper cover. AL-1551CS DISASSEMBLY AND ASSEMBLY 8 - 15...
  • Page 56 4) Remove two screws and remove the multi feed bracket unit from 6) Remove the pick-up roller. the multi paper feed upper frame. 7) Cut the binding band and remove the multi paper feed solenoid. Remove three E-rings and remove the manual paper feed roller Multi paper feed solenoid C.
  • Page 57: Rear Frame Section

    D. Pressure plate holder attachment 2) Disconnect the connector. 3) Remove two screws, and remove the scanner motor. 1) Attach the pressure plate holder so that the resin section is not covered with the seal M1-N. Seal M1-N Pressure plate holder Attachment reference...
  • Page 58: Power Section

    8. Power section 1) Remove the belt, the paper feed frame Spring, and two harnesses. 2) Remove the pickup unit. A. List Part name Ref. Power PWB B. Disassembly procedure 1) Disconnect each connector. 2) Remove the screw, and remove the earth line. 3) Remove two screws, and remove the power PWB unit.
  • Page 59 B. Pickup solenoid D. Manual paper feed roller, pickup roller 1) Remove two screws. 1) Lift the paper stopper. 2) Remove the pickup solenoid 2) Slide the take-up roller unit. 3) Slide the bushing in the direction of the arrow. 4) Remove the take-up roller unit.
  • Page 60 E. Belt G. Paper entry sensor 1) Remove the belt. 1) Loosen the screw. 2) Open the paper exit paper guide. 3) Remove the paper entry sensor. 4) Remove the harness. H. PS roller 1) Remove the parts. F. SPF motor 2) Remove the paper supply roller.
  • Page 61: Nd Cassette Section

    10. 2nd cassette section 1) Open the right cabinet. 2) Remove three screws. Part name Ref. 3) Remove one connector from MCU. Paper sensor 4) While tilting down the 2nd connection arm A, pull and remove the Cassette detection SW paper feed unit toward you.
  • Page 62 B. Cassette detection switch E. Paper feed clutch 1) Remove the pawl. 1) Remove the E-ring. 2) Remove the cassette detection switch. 2) Remove the paper feed clutch. 3) Remove the harness. 3) Remove the parts. C. Paper feed solenoid 1) Remove the screw.
  • Page 63: Duplex Motor Section (Rspf Model Only)

    11. Duplex motor section (RSPF model C. Remove the Duplex motor. only) 1) Remove two screws. 2) Remove the Duplex motor cover. A. Remove the rear cabinet. 3) Remove the Duplex motor. 1) Remove four screws. 2) Remove the rear cabinet. B.
  • Page 64: Rspf Section (Rspf Model Only)

    13. RSPF section (RSPF model only) C. Upper cover 1) Remove four screws from the bottom of the main body. A. RSPF 2) Remove the upper cover. (1) Remove the rear cabinet. 1) Remove four screws. 2) Remove the rear cabinet. (2) Remove the RSPF.
  • Page 65 E. Upper cover of the pickup unit. G. Pickup solenoid 1) Remove two screws from the bottom of the pickup unit. 1) Remove two screws. 2) Remove the upper cover. 2) Remove the pickup solenoid. F. Sensor PWB 1) Remove two screws. 2) Remove the sensor PWB.
  • Page 66 (2) Remove the clutch (2) Remove the Manual paper feed roller, pickup roller. 1) Remove the E-ring. 1) Remove the parts. 2) Remove the parts. 2) Remove the manual paper feed roller. 3) Remove the pickup roller. 4) Remove the parts. I.
  • Page 67 K. Belt 1 M. SPF motor 1) Remove the belt. 1) Remove the harness. 2) Remove two screws. 3) Remove the SPF motor. N. Solenoid 1) Remove the harness. 2) Remove two screws. L. Belt 2 3) Remove the solenoid. 1) Remove three screws.
  • Page 68 O. Clutch (2) Remove the paper supply roller. 1) Loosen the screw. 1) Cut the band with nippers. 2) Open the paper exit paper guide. 2) Remove the harness. 3) Remove the parts. 3) Remove the clutch. 4) Remove the paper supply roller. Q.
  • Page 69 R. Transport roller 1. (3) Remove the transport roller. 1) Remove the paper exit paper guide. (1) Remove the parts. 2) Remove the transport roller. 1) Remove the parts. (2) Remove the parts. 1) Loosen the screw. 2) Open the paper exit paper guide. 3) Remove the parts.
  • Page 70 (2) Remove the paper feed paper guide upper. T. Solenoid 1) Remove two screws. (1) Remove the reverse gate 2) Remove the paper feed paper guide upper. 1) Remove the ring 2) Remove the reverse gate (3) Remove the paper exit roller. Note: When reassembling, be careful of the groove and the hole 1) Remove the parts.
  • Page 71: Adjustments

    [9] ADJUSTMENTS 5) Calculate the main scanning direction magnification ratio. Main scanning direction magnification ratio Copy image dimensions 1. Optical section X 100 (%) Original dimension A. Copy magnification ratio adjustment (When a 100mm scale is used as the original.) The copy magnification ratio must be adjusted in the main scanning Original (Scale) HARDENED...
  • Page 72 c. Adjustment procedure B. Image position adjustment 1) Set the scale on the document table as shown below. (Use a long There are following five kinds of image position adjustments, which are scale for precise adjustment.) made by laser control except for the image scan start position adjustment.
  • Page 73 (1) Lead edge adjustment (2) Image rear edge void amount adjustment 1) Set a scale to the center of the paper lead edge guide as shown 1) Set a scale to the rear edge section of A4 or 11" x 8 1/2" paper size below, and cover it with B4 or 8 1/2"...
  • Page 74: Copy Density Adjustment

    3) Make a copy and check that the copied center line is properly Test chart comparison table positioned. UKOG- The standard value is 0 ±2mm from the paper center. 0162FCZZ DENSITY 2.0mm or less (Copy A) Copy image UKOG- 0089CSZZ Copy paper 0.5 1.9 Shift...
  • Page 75: High Voltage Adjustment

    Auto T/S mode Auto lamp/Photo lamp ON "3" is slightly copied. 3) Make a copy. Check the adjustment level (shown in the above table) of the exposure test chart (Sharp Gray Scale). Sharp Gray Scale adjustment level Non toner save mode...
  • Page 76: Duplex Adjustment

    4. Duplex adjustment A. Adjusting the paper reverse position in memory for duplex copying This step adjusts the front surface printing (odd-number pages of a document set) in the S-D mode copying and the leading edge position of an image on even-number pages in the D-S mode. That is, it covers the adjustment of the second surface printing mode (image loss at the front edge of an image) in which image data is once stored in memory.
  • Page 77 4) Execute simulation 50-19 to turn on the TEXT lamp and make the printing mode in OC-D mode. Make a copy of the test chart to check the void area of the scale on the image. Void position to be check Paper The trailing edge void on the first printing surface is shown above.
  • Page 78: Simulation, Trouble Codes

    [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 of entering the simulation mode Start Is there a sub Press the COPY key.
  • Page 79: List Of Simulations

    2. List of simulations Kind of Operation Kind of main code code Operation main code code Various setup Manual feed setup Optical system Mirror scan operation (R) SPF setup Aging of mirror scanning Second cassette setup SPF Individual SPF sensor status display Machine duplex setup load operation Motor ON...
  • Page 80: Contents Of Simulations

    3. Contents of simulations Input method: Clear key → Exposure Select key → Clear key → Exposure Select key Main Content code code Mirror scan operation (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...
  • Page 81 Main Content code code Copy lamp ON (Operation/Procedure) When the START key is pressed, the copy lamp is lighted for 5 sec. Paper feed solenoid ON (Operation/Procedure) When the START key is pressed, the paper feed solenoid selected by the tray select key repeats ON (500ms) and OFF (500ms) 20 times.
  • Page 82 Main Content code code Printer counter display The display method is the same as the total count value display. Scanner mode counter display The display method is the same as the total count value display. Scanner counter display The display method is the same as the total count value display. SPF JAM counter display The display method is the same as the total count value display.
  • Page 83 Main Content code code Destination setup When this simulation is executed, the current setup of the destination code number is displayed. Enter the code number corresponding to the destination and press the PRINT switch to enable the setup. Code number Destination Inch series EX JAPAN AB series...
  • Page 84 Main Content code code Transfer ON timing control setup (Operation/Procedure) 1. When this simulation is executed, the currently set code number is displayed. 2. Enter the code number and press the START key, and the setting will be changed. (For any number different from the following ones, the default time is automatically set.) Code number Setting...
  • Page 85 Main Content code code Paper sensor status display Indicates the paper sensor status using the lamps on the operation panel. Sensor name Display lamp Before-resist paper sensor (PPD1) Developer cartridge replacement lamp Fusing section paper sensor (PPD2) JAM lamp Paper exit sensor (POD) Photoconductor cartridge replacement lamp 2nd CS paper sensor (PPD3) 2nd cassette lamp...
  • Page 86 Main Content code code Copy density adjustment (300dpi) Used to set the copy density in each mode. (Operating procedure) When this simulation is executed, warm-up and shading operations are performed and the current setup is displayed in two digits (default: 50). Change the setup value with the copy quantity keys.
  • Page 87 Main Content code code γ table setup or AE operation mode setup When this simulation is executed, the current setup of the gamma table code number is displayed. (Default: Japan = 1, EX Japan = 2) Enter the code number corresponding to desired gamma table, and press the PRINT switch or the copy mode select key to enable the setup.
  • Page 88 Main Content code code Copier color reproduction setup Used to set color reproduction for each mode. Colors which are easily copied or which are not easily copied are selected. Setup value Easy-to-copy colors Difficult-to-copy colors Purple/Blue/Red Yellow/Green/Light blue Light blue/Green/Blue Purple/Red/Yellow Yellow/Red/Green Blue/Light blue/Purple...
  • Page 89 Main Content code code Flash ROM program writing mode (Operating procedure) When this simulation is executed, “d” is displayed on the display and the machine enters the Flash ROM program writing mode. Use the writing tool to write the program from PC. During writing, the display indicates as shown below. After completion of downloading, turn OFF/ON the power to reset.
  • Page 90 Main Content code code Center offset adjustment Used to adjust the copy image position on the copy paper and the center offset position when scanning a document. (Operating procedure) When this simulation is executed, the current setup value is displayed. Enter the adjustment value with the 10-key and press the PRINT switch, and the entered value will be saved and a copy will be made.
  • Page 91 Main Content code code Resist quantity adjustment Used to adjust the contact pressure of paper against the machine resist roller and the RSPF resist roller. (Operating procedure) When this simulation is executed, the current setup value is displayed. Enter the adjustment value with the 10-key and press the PRINT switch, the entered set value will be saved and a copy will be made. When the clear key is pressed, the entered value will be saved and the machine will exit from the simulation mode.
  • Page 92: Trouble Codes

    4. Trouble codes A. Trouble codes list Main Trouble content Detail of trouble code code Duplex model memory The memory is not set properly or the memory capacity is not set to the duplex setup (6M). setup error, memory not- Cancel method: Set SIM 26-39 code number to 2.
  • Page 93: User Programs

    [11] USER PROGRAM The conditions of factory setting can be changed according to the use conditions. 1. Functions that can be set with user programs Function Contents Factory setting Auto clear • When a certain time is passed after completion of copying, this function returns to the initial state automatically.
  • Page 94: Density Level Adjustment

    3. Density level adjustment 4. Toner save mode setup and cancel A. AE level adjustment (OC mode) [Input procedure] When the density select key is pressed and held for 5 sec after turning [Input procedure] on the [TEXT] mode lamp, the [PHOTO] mode lamp blinks and the cur- When the density select key is pressed and held for 5 sec after turning rent setup of the density level is displayed.
  • Page 95: Electrical Section

    [12] ELECTRICAL SECTION 1. Block diagram A. Overall block diagram AL-1551CS ELECTRICAL SECTION 12 - 1...
  • Page 96 B. MCU PWB unit AL-1551CS ELECTRICAL SECTION 12 - 2...
  • Page 97: Circuit Descriptions

    2. Circuit descriptions Input/ Signal code Operating Output A. Main PWB (MCU) Data I/O Data bus Data I/O Data bus (1) General Data I/O Data bus The MCU PWB is composed of: Data I/O Data bus • CPU peripheral sections which perform mechanical sequence Data I/O Data bus control and function job management...
  • Page 98 (3) Image process ASIC (HG73C119HF) Input/ Signal code Operating Output a. General USBIN Input IF PWB detection signal The ASIC is composed of the three major blocks: the image process Input section, the print control section, and the I/F section. Input Image process section: Avss...
  • Page 99 Connected Connected Signal Name IN/OUT Description Signal Name IN/OUT Description 16 ope_latch Tr array IC Operation circuit latch 49 mircnt Buffer IC SPF scanner select signal. Data take-in at signal "L" 50 GND(AC) Power 17 op_data Tr array IC Operation circuit data 51 pcl_s_print (Not used) signal...
  • Page 100 Connected Connected Signal Name IN/OUT Description Signal Name IN/OUT Description 86 ie1284_parad0 IN/OUT I/F board DATA bus (IEEE1284 118 GND(CORE/DC) Power connector communication port) 119 ram_data11 IN/OUT SDRAM SDRAM (Image 87 suspend I/F board SUSPEND signal process page connector (USB communication memory) data bus port) 120 ram_data10...
  • Page 101 Connected Connected Signal Name IN/OUT Description Signal Name IN/OUT Description 145 ram_mad7 SDRAM SDRAM (Image 189 afp_data0 CCD PWB Image scan data process page 190 GND(CORE/DC) Power memory) address bus 191 sfclk Clock 146 VCC(AC) 192 tm2_24m (Not used) 147 ram_mad6 SDRAM SDRAM (Image 193 GND(PLL)
  • Page 102 (3) Reset circuit Connected Signal Name IN/OUT Description This circuit detects ON/OFF of power to control start/stop of each cir- cuit. The 3.3V voltage of the main PWB is detected by the reset IC to 235 cpudata10 IN/OUT CPU CPU data bus generate the reset signal.
  • Page 103 [When the heat roller surface temperature is lower than the set (5) Driver circuit (Solenoid) level] a. Outline 1) Since the thermistor terminal voltage is higher than the set level, Since the load signal from the CPU or the ASIC cannot drive the load the HL signal from the CPU becomes HIGH.
  • Page 104 (8) Mirror motor control circuit, Duplex motor control circuit Stepping motors are employed for the mirror motor, the SPF motor, and the duplex motor. The driver for IC127 (for mirror motor) is the bipolar drive L6219DS, and the driver for IC128 (for SPF) is the uni- polar drive IC MTD1361F.
  • Page 105 (9) Operation circuit c. IEEE1284 circuit The IEEE1284 driver is used to perform interface between the ASIC a. General (engine) and the host. The operation circuit is composed of the key matrix circuit and the dis- play matrix circuit. IEEE1284 b.
  • Page 106 (1) Noise filter circuit (3) Inverter and control circuit (Flyback converter system) The filter circuit is composed of L and C. It reduces common noises D103 and normal mode noises generated from the AC line. T001 The common noise means that generated in each line for GND. Its noise component is delivered through C001, C003, and C007 to GND.
  • Page 107 The control circuit is subject to negative feedback from the secondary side as shown in fig (4). A photo coupler (PC002) is employed to insu- late between the primary side and the secondary side to feed back the control signal to the primary side. When the output voltage is increased by energy transmission from T001, the voltage detected by R109 and R111 is compared with the reference voltage of IC102.
  • Page 108: Circuit Diagram

    [13] CIRCUIT DIAGRAM AL-1551CS CIRCUIT DIAGRAM 13 - 1...
  • Page 109 AL-1551CS CIRCUIT DIAGRAM 13 - 2...
  • Page 110 AL-1551CS CIRCUIT DIAGRAM 13 - 3...
  • Page 111 AL-1551CS CIRCUIT DIAGRAM 13 - 4...
  • Page 112 AL-1551CS CIRCUIT DIAGRAM 13 - 5...
  • Page 113 AL-1551CS CIRCUIT DIAGRAM 13 - 6...
  • Page 114 AL-1551CS CIRCUIT DIAGRAM 13 - 7...
  • Page 115 AL-1551CS CIRCUIT DIAGRAM 13 - 8...
  • Page 116 AL-1551CS CIRCUIT DIAGRAM 13 - 9...
  • Page 117 AL-1551CS CIRCUIT DIAGRAM 13 - 10...
  • Page 118 Shield AL-1551CS CIRCUIT DIAGRAM 13 - 11...
  • Page 119: Power Supply

    4. POWER SUPPLY POWER SUPPLY (120V/127V) AL-1551CS CIRCUIT DIAGRAM 13 - 12...
  • Page 120 AL-1551CS CIRCUIT DIAGRAM 13 - 13...
  • Page 121: Actual Wiring Diagram

    5. ACTUAL WIRING DIAGRAM ACTUAL WIRING DIAGRAM 1/7 Cassette paper Paper out Resist roller Cassette detect detecter Solenoide Solenoide cassette CN104 D-GND D-GND VCC3 EN5V EN5V USBIN D_CONT VPOUT VMOUT VPIN VMIN interface SUSPEND PARAD0 PARAD1 PARAD2 PARAD3 PARAD4 PARAD5 PARAD6 (GDI) PARAD7...
  • Page 122 Cassette detect Paper pass detect Scanner cassette CN102 D-GND (ONL ) (PSL ) EN5V D-GND SELIN3 SELIN2 SELIN1 OP-DATA Operational PWB OP-LATCH OP-CLK (BEO) (KIN1 ) (KIN2 ) DRST D-GND 18FE-BT-VK-N CN105 PGND PGND EN5V D-GND VSAMP CCD-TG D-GND CCD-RS BSAMP CCD-CP AFE_SDI...
  • Page 123 ACTUAL WIRING DIAGRAM 2/7 (POWER UNIT) CN106 DV UNIT DVSEL D-GND B4B-PH-K-R CN10 DV-BIAS F-GND CN101 INT24V INT24V INT24V INT24V HIGH VOLTAGE /BIAS /BIAS POWER SUPPLY UNIT /GRIDL /GRIDL Thermostat D-GND PGND D-GND CN101 CN002 3.3VIN D-GND Heater 5VEN PGND 3.3VIN D-GND Lamp...
  • Page 124 ACTUAL WIRING DIAGRAM 3/7 (SCANNER UNIT) CN105 PGND PGND PGND LAMP PGND PGND INVERTER LAMP D-GND D-GND AFE_OBE AFE_OBE VSAMP VSAMP CCD-TG CCD-TG D-GND D-GND CCD-RS CCD-RS BSAMP BSAMP CCD-CP CCD-CP AFE_SDI AFE_SDI CCD-PHI2 CCD-PHI2 CCD PWB D-GND D-GND CCD-PHI1 CCD-PHI1 AFE_SEN AFE_SEN...
  • Page 125 ACTUAL WIRING DIAGRAM 4/7 (INTERFACE) C C C USB_CN CN104 D-GND D-GND /D STB D-GND D-GND DATA0 VCC3 VCC3 DATA1 EN5V EN5V DATA2 EN5V EN5V DATA3 USBIN USBIN DATA4 D_CONT D_CONT DATA5 VPOUT VPOUT DATA6 VMOUT VMOUT DATA7 /ACK BUSY VPIN VPIN VMIN...
  • Page 126 ACTUAL WIRING DIAGRAM 5/7 (SPF, R-SPF UNIT) CN105 D-GND /SPUS PU SOLENOID SPPD D-GND PULUP5V PULUP5V SPID D-GND SPF SENSOR SDSW SPPD SB4D CN101 D-GND D-GND /SPUS SDSW SDSW SPID SPID SENSOR PWB SPMT-1 SPMT-3 SPMT-3 24VM SPMT-2 SPMT-1 SPMT-0 SPMT-0 MOTOR 24VM...
  • Page 127 ACTUAL WIRING DIAGRAM 6/7 (2ND PAPER FEEDING UNIT) CN115 /CPFS2 /CPFS2 PF SOLENOID OED2 TRAY DETECT PPD3 D-GND SWITCH D-GND D-GND D-GND PPD3 PHOTO SENSOR D-GND OED2 D-GND 2nd Paper feeding unit CN115 /CPFS2 /CPFS2 /CPFS2 PF SOLENOID OED2 TRAY DETECT PPD3 PPD3 D-GND...
  • Page 128 ACTUAL WIRING DIAGRAM 7/7 (MANUAL PAPER FEEDING UNIT) CN123 /MPFS Multi feeding solenoid B5B-PH-K-R Multi Manual Paper Feeding unit CN123 MFD sensor PWB PULUP5V D-GND B5B-PH-K-R Single Manual Paper Feeding unit Manual Paper Feeding unit AL-1551CS CIRCUIT DIAGRAM 13 - 21...
  • Page 130 CAUTION FOR BATTERY DISPOSAL (For USA,CANADA) Contains lithium-ion battery. Must be disposed of properly. Remove the battery from the product and contact federal or state environmental agencies for information on recycling and disposal options.
  • Page 131 COPYRIGHT 2002 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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