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Sharp AL-1600 Service Manual

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[ 1 ] GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
[ 2 ] SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
[ 3 ] CONSUMABLE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
[ 4 ] EXTERNAL VIEWS AND INTERNAL STRUCTURE . . . . . . . . . . . . . . . 4-1
[ 5 ] UNPACKING AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
[ 6 ] OPERATIONAL DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
[ 7 ] ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
[ 8 ] SIMULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
[ 9 ] USER PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
[10] TROUBLE CODE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
[11] DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
[12] ELECTRICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
[13] CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
[14] ACTUAL WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Parts marked with "!" 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.
CONTENTS
SHARP CORPORATION
CODE: 00ZAL1610//A1E
DIGITAL COPIER
AL-1600
AL-1610
MODEL
This document has been published to be used
for after sales service only.
The contents are subject to change without notice.
AL-1610

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  Summary of Contents for Sharp AL-1600

  • Page 1 AL-1610 CODE: 00ZAL1610//A1E DIGITAL COPIER AL-1600 AL-1610 MODEL CONTENTS [ 1 ] GENERAL ..........1-1 [ 2 ] SPECIFICATIONS .
  • Page 2 AL-1610 Warning! This product is a class A product. If it is operated in households, offices or similar surroundings, it can produce radio interferences at other appliances, so that the user has to take adequate countermeasures. CLASS 1 LASER PRODUCT VAROITUS! LAITTEEN KÄYTTÄMINEN MUULLA KUIN TÄSSÄ...
  • Page 3: Table Of Contents

    AL-1610 CONTENTS [ 1 ] GENERAL [ 9 ] USER PROGRAM ....... 1-1 .
  • Page 4: Model

    AL-1610 [1] GENERAL 1. General 4. Copier installation This model is a digital personal copier produced with key words of Do not install your copier in areas that are: "Comfort able copy, Clear copy, Easy copy" providing high copy per- •...
  • Page 5: Specifications

    Single except for recycled paper (1) Basic speed (3) Optional paper feed unit 1 scan 1 copy 16 sheets/min 1-step paper feed unit 2-step paper feed unit 1 scan multi copy AL-1600 Not available Standard/Option Not available Not available AL-1610 Available F. Multi copy Condition: Copy speed in the normal copy from all the paper feed ports including the manual paper feed port.
  • Page 6 256 gradations Auto tray switching Writing Binary Message display User program Total counter O. Machine composition Model AL-1600 16 CPM standard model AL-1610 16 CPM standard model (With shifter) (1) Supply parts Part name Toner/developer cartridge AL-160-TD-B Drum cartridge AL-160-DR P.
  • Page 7: Consumable Parts

    AL-1610 [3] CONSUMABLE PARTS 1. Supply system table A. USA Name Content Life Product name Package Remark × 1 Developer cartridge (Black) Toner/developer cartridge 15K AL-160TD Life setting by A4 6% (Toner: 600g, Developer: 400g) documents × 1 Postcard label (TLABZ0025YSZZ) ×...
  • Page 8: Environment Conditions

    AL-1610 2. Environment conditions 3. Production number identification A. Transport condition <Developing cartridge> The label on the drum cartridge shows the date of production. (1) Transport conditions Destination Serial number Production (∗) (00001-99999) month January Indicates production in China. The end digit of production year September ∗: Destination October...
  • Page 9: External Views And Internal Structure

    AL-1610 [4] EXTERNAL VIEWS AND INTERNAL STRUCTURES 1. Appearance Original cover Original table (OC table) Handles Power switch Operation panel Paper output tray Original size detector Front cover Paper tray Side cover Side cover handle Bypass tray guides Bypass tray 2.
  • Page 10: Operation Section

    Ready lamp key indicator will light up. Press the START key to restart copy- Other lamps ing. For best copying results, be sure to use only SHARP Genuine Copy is Energy Supplies which are designed, engineered and tested to maxi-...
  • Page 11: Motor, Solenoid, Clutch

    AL-1610 4. Motor, solenoid, clutch Name Code Function, operation Exhaust fan motor Cools the inside of the machine. Shifter motor Shifts the paper exit tray. (AL-1610) Toner motor Toner supply Mirror motor Drives the optical mirror base (scanner unit). Cooling fan motor Cools the inside of the machine.
  • Page 12: Sensor, Switch

    AL-1610 5. Sensor, switch Name Code Function, operation Mirror home position sensor MHPS Detects the mirror (scanner unit) home position. Cassette detection switch CSD1 Cassette detection Toner density sensor Toner quantity detection Paper exit sensor (paper exit side) POD1 Detects paper exit. Right door switch DSWR Side door open/close detection...
  • Page 13: Pwb Unit

    AL-1610 6. PWB unit Name Function, operation Copy lamp invertor PWB Copy lamp control Power PWB AC power input/DC power control High voltage PWB High voltage control CCD sensor PWB Image scanning Main PWB (MCU) Machine control/Image process Paper exit interface PWB Paepr exit, finishing control Operation main PWB Operation panel input/Display, operation panel section control...
  • Page 14: Cross Sectional View

    AL-1610 7. Cross sectional view Name Function/Operation Copy lamp Image radiation lamp Copy lamp unit Operates in synchronization with No. 2/3 mirror unit to radiate documents sequentially. LSU unit Converts image signals into laser beams to write on the drum. Lens unit Reads images with the lens and the CCD.
  • Page 15: Unpacking And Installation

    AL-1610 5) Gently pull the TD cartridge out while holding the handle. [5] UNPACKING AND 6) Hold the strap on the cartridge and remove the TD cartridge up- INSTALLATION ward. TD cartridge handle 1. Unpaking procedure Be sure to hold the handles on both sides of the copier by two persons to unpack the copier and carry it to the installation location.
  • Page 16 AL-1610 11) Raise the handle of the paper tray and pull the paper tray out 14) Push the pressure plate down until it locks in place. until it stops. 15) Squeeze the lock lever of the front guide and slide the front guide to match the width of the paper.
  • Page 17: Outline

    AL-1610 G. Fusing: Fusing section [6] OPERATIONAL DESCRIPTIONS • Heat and a pressure are applied to the toner image on the copy paper to fuse the image on the paper. 1. Outline of operation The outline of operation is described referring to the basic configura- 2.
  • Page 18: Process Section

    AL-1610 B. Basic structure of scanner section Copy lamp (Xenon lamp) Generate photo energy to scan documents. Reflector (Converging plate) Collects light emitted from the copy lamp and radiate the document. No. 1 mirror Refracts the reflection light from the document to No. 2 mirror. No.
  • Page 19 AL-1610 Operation cycle Paper exit roller Heat roller Paper exit Fusing Separation Separation charger High voltage power Cleaning blade Cleaning Waste toner box Transfer Main charger Transfer charger High voltage power High voltage power Charging Transfer Synchronization Resist roller with drum Exposure Developing Laser beam...
  • Page 20 AL-1610 (2) Exposure Non-image area A Laser beam is generated from the semiconductor laser and control- -600 led by the print pattern signal. The laser writes onto the OPC drum surface through the polygon mirrors and lens. The resistance of the OPC layer decreases for an area exposed by the laser beam (cor- -400 responding to the print pattern signal).
  • Page 21: Laser Unit

    AL-1610 <4> Stop (7) Optical discharge (Semiconductor laser) The reverse sequence takes place. Before the drum rotation is stopped, the semiconductor laser is radiated onto the drum to reduce the electrical resistance in the OPC c. Retaining developing bias at an abnormal occurrence layer and eliminate residual charge, providing a uniform state to the <1>...
  • Page 22: Paper Feed Section

    AL-1610 Makes the laser scanning speeds at both ends of the drum same as B. Laser beam path each other. a ≠ b ≠ c d = e = f 5. Paper feed section A. Basic structure No. 1 cassette paper feed roller (Semi-circular roller) Picks up paper from No.
  • Page 23: Fusing Section

    AL-1610 (2) Manual paper feed tray operation B. Heat roller Select the manual paper feed tray and press the START button, and A pressure roller is used for the heat roller and a silicone rubber roller the manual paper feed roller will be turned on to bring the paper feed is used for the lower heat roller for better toner fusing performance roller in contact with paper and lift the shutter simultaneously.
  • Page 24: Adjustments

    AL-1610 [7] ADJUSTMENTS 1. Adjustment item list Section Adjustment item Adjustment procedure/SIM No. Process section Developing bias voltage output adjustment SIM 8-1 Main charger voltage output adjustment SIM 8-2/SIM 8-3 Transfer charger current adjustment SIM 8-6 Mechanism section Image position adjustment SIM 50-1/SIM 50-10 Main scanning direction (FR direction) No.
  • Page 25 AL-1610 2) Set the document size to A4, and make two copies at 100%. B. Mechanism section 3) Check the second copy. If necessary, perform the following ad- (1) Image position adjustment (SIM 50-1/SIM 50-10) justment procedure. a. Image lead edge pasition adjustment * The first copy does not show the void.
  • Page 26 AL-1610 <Adjustment specification> 3) Manually turn the mirror base drive pulley and bring No. 2/3 mirror base unit into contact with the positioning plate. Mode Specification Set value Set range At that time, if the front frame side and the rear frame side of No. Left edge void 1 ~ 4mm 1 step:...
  • Page 27 AL-1610 6) Put No. 2/3 mirror base unit on the positioning plate again, push 2) Open the original cover and make a normal (100%) copy. the projections on the front frame side and the rear frame side of 3) Measure the width of the black background at the lead edge and the copy lamp unit to the corner frame, and tighten the wire fixing at the rear edge.
  • Page 28 AL-1610 1) Making of a test sheet • When La > Lb Shift the mirror base B rail upward by the half of the difference Make test sheet by drawing parallel lines at 10mm from the both ends of A3 (11" x 17") white paper as shown below. (These lines of La –...
  • Page 29 AL-1610 • Error in the auto correction mode 2) Set the test chart on the SPF and make a normal (100%) copy. 3) Compare the scale image and the actual image. If necessary, Display Content Major cause perform the following adjustment procedures. •...
  • Page 30 4) After warmup, shading is performed and the current set value of <Adjustment specification> the off center adjustment at each paper feed port is displayed on Density Display Exposure Sharp Gray Set value the display section in 2 digits. mode lamp level...
  • Page 31: Simulations

    AL-1610 [8] SIMULATION Main Contents code code JAM memory display 1. Entering the simulation mode Total JAM counter display Total counter display Perform the following procedure to enter the simulation mode. Developing counter display Clear key → Interruption key → Shift key → Interruption key → Start key →...
  • Page 32: Contents Of Simulations

    AL-1610 4. Contents of simulations Main Initial Contents Details of operation Set range code code value Mirror unit operation Used to execute scanning at the speed corresponding to the set mag- 100% 50 ~ 200% check nification ratio. Key operation Display Changing the magnification ratio: Set magnification ratio:...
  • Page 33 AL-1610 Main Initial Contents Details of operation Set range code code value Job separator operation Used to drive the job separator one way. Pressing the clear key stops check the job separator at the home position. Key operation Stops at the home position: Clear all key Job separator home Used to drive the job separator to the home position.
  • Page 34 AL-1610 Main Initial Contents Details of operation Set range code code value Aging without JAM with Used to start warmup and count and display the warmup time every 1 ~ 99 warmup time display second. After completion of warmup, count up is terminated and the ready lamp is lighted.
  • Page 35 AL-1610 Main Initial Contents Details of operation Set range code code value Used to clear the maintenance counter. ∗2 Maintenance counter clear Maintenance cycle setting Used to display the currently set maintenance cycle at the numbers shown at right. When the set value is entered and the start key is pressed, the set value is stored.
  • Page 36 AL-1610 Main Initial Contents Details of operation Set range code code value Used to display the current duplex print counter value. ∗1 Duplex print counter display Used to display the current copy counter value. ∗1 Copy counter display Used to display the current printer counter value. ∗1 Printer counter display Used to display the current electronic sort counter value.
  • Page 37 AL-1610 Main Initial Contents Details of operation Set range code code value Used to set the print counter mode in A3 or 11" × 17". Counter mode setting Used to display the currently set counter value with the numbers at right. After entering the set value, press the start key, and the set value is stored.
  • Page 38 AL-1610 Main Initial Contents Details of operation Set range code code value Document sensor light Used to display the light reception level and the detection level of the reception level display document sensor. (The sensor level adjusted with SIM 41-2 is dis- played.) Key operation Display...
  • Page 39 AL-1610 Main Initial Contents Details of operation Set range code code value OC mode sub scanning After completion of warmup, shading is performed and the currently set 1 ~ 99 direction magnification OC mode sub scanning direction magnification ratio adjustment in copy- ratio adjustment in copying ing is performed.
  • Page 40 AL-1610 Main Initial Contents Details of operation Set range code code value OC mode document off After completion of warmup, shading is performed and the currently set center adjustment off center adjustment value for the document in OC reading is displayed. For the adjustment procedure, refer to the previous descriptions.
  • Page 41: User Program Functions

    AL-1610 [9] USER PROGRAM The factory setting can be changed according to the operating conditions. 1. User program functions Function Outline Default Auto clear When a certain time is passed after completion of the machine operation, the mode is returned to 60 sec the initial state automatically.
  • Page 42: Trouble Code List

    AL-1610 [10] TROUBLE CODE LIST Classification Function Main code Sub code Trouble name Remark Electrical Copier Thermistor open error Thermistor is open system error Fusing temperature abnormality Abnormally high fusing temperature (Abnormally high temperature detection) Fusing temperature abnormality Abnormally low fusing temperature (Abnormally low temperature detection) Media sensor error Document detection error...
  • Page 43 AL-1610 Classification Function Main code Sub code Trouble name Remark Electrical Operation Operation board communication trouble system error Operation board communication trouble (Protocol) Operation board communication trouble (Parity) Operation board communication trouble (Overrun) Operation board communication trouble (Framing) Operation board communication trouble (Timeout) Zero cross Zero cross trouble...
  • Page 44: High Voltage Section

    AL-1610 B. Charger wire [11] DISASSEMBLY AND Installation: The spring tip must be between two reference ribs. ASSEMBLY • The charger wire must be free from twist or bending. • Be sure to put the charger wire in the V groove. WARNING: Before performing the disassembly procedure, be sure to remove the power cord to prevent against an electric shock.
  • Page 45: Fusing Section

    AL-1610 B. Copy lamp unit D. Lens unit Disassembly: Be sure to put No. 2/3 mirror unit to the positioning plate (A). Assembly: Put the notched surface of wire holder (3) downward, tighten temporarily, and install. Adjustment: Main scanning direction distortion balance adjustment 3.
  • Page 46 AL-1610 Assembly: Put the paper guide earth spring (A) under the paper B. Thermostat guide (B) before fusing. C. Thermistor Installation: Check that the thermistor is in contact with the upper heat roller. Disassembly: There are three pawls on the fusing cover. Remove the screws and slide the fusing cover to the right to remove.
  • Page 47: Paper Exit Section

    AL-1610 E. Upper heat roller G. Lower heat roller Assembly: When installing the paper guide (3) before fusing, tighten the paper guide fixing plate so that the paper guide fixing plate (2) is in contact with the frame bottom section (A) under fusing.
  • Page 48 AL-1610 B. Paper exit unit removal D. Paper exit roller C. Transport roller 11 – 5...
  • Page 49: Mcu

    AL-1610 Assembly: Insert the spring pin so that the waveform (A) of the 6. Optical frame unit spring pin faces in the longitudinal direction of the paper exit drive gear long hole (B). Content Be sure to insert two ribs (C) into the groove (D). Optical frame unit A.
  • Page 50: Tray Paper Feed Section/Paper Transport Section

    AL-1610 Assembly: Do not miss the door lock pawl. • Adjustment: Image lead edge position adjustment • Image left edge position adjustment • Paper off-center adjustment 8. Tray paper feed section/Paper transport section B. Drive unit Assembly: Move down the clutch pawl as shown below, and avoid Content the clutch and install.
  • Page 51: Manual Multi Paper Feed Section

    AL-1610 C. Solenoid (paper feed solenoid, resist roller E. Paper feed clutch/Paper feed roller solenoid) (Semi-circular roller) D. Resist roller clutch/Resist roller 9. Manual multi paper feed section Content Manual multi paper feed section Manual transport clutch Manual paper feed clutch Manual transport roller/Manual paper feed roller Multi feed solenoid A.
  • Page 52 AL-1610 Disassembly: Set up the cam transmission arm (2), and remove it. B. Manual transport clutch Assembly: Install so that the cam transmission arm (2) is under the roller arm (A). C. Manual paper feed clutch Disassembly: Set up the shutter arm (1) then remove it. Assembly: Install so that the boss section of the fulcrum arm (2) comes between ribs.
  • Page 53: Power Section

    AL-1610 D. Manual transport roller/Manual paper feed roller 10. Power section Installation: Be careful of the installing direction of themanual Content transport roller (4). Power unit A. Power unit E. Multi feed solenoid Assembly: Install so that the latches (A) and (B) move smoothly. 11 –...
  • Page 54 AL-1610 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.

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