Sharp AL-1000, AL-1010 Service Manual. Parts Guide

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SERVICE MANUAL

CODE:00ZAL1000/A1E

DIGITAL COPIER

AL-1000/1010

AL-1000

MODEL

CONTENTS

[ 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 ] COPING 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 PROGRA MS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 – 1

[12] ELECTRICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 – 1

AL-1010

[13] CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 – 1

Parts marked with " " is important for maintaining the safety of the set. Be sure to replace these parts with specified ones for maintain in g th e sa fty and performance of the set.

SHARP CORPORATION

This document has been published to be used for after sales service only. The contents are subject to change without notice.

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.

This laser radiation is not a danger to the skin, but when an exact focusing of the laser beam is achieved on the eye’s retina, there is the danger of spot damage to the retina.

The following cautions must be observed to avoid exposure of the laser beam to your eyes at the time of servicing.

1) When a problem in the laser optical unit has occurred, the whole optical unit must be exchanged as a unit, not as individual parts.

2) Do not look into the machine with the main switch turned on after removing the developer unit, toner cartridge, and drum cartridge.

3) Do not look into the laser beam exposure slit of the laser optical unit with the connector connected when removing and installing the optical system.

4) The middle frame contains the safety interlock switch.

Do not defeat the safety interlock by inserting wedges or other items into the switch slot.

LASER WAVE – LENGTH : 780 ~ 795 Pulse times : 0.481ms/6mm Out put power : 0.20 ± 0.03mW

CAUTION

INVISIBLE LASER RADIATION, WHEN OPEN AND INTERLOCKS DEFEATED. AVOID EXPOSURE TO BEAM.

VORSICHT

UNSICHTBARE LASERSTRAHLUNG, WENN ABDECKUNG GEÖFFNET UND SICHERHEITSVERRIEGELUNG ÜBERBRÜCKT. NICHT DEM STRAHL AUSSETZEN.

VARO !

AVATTAESSA JA SUOJALUKITUS OHITETTAESSA OLET ALTTIINA NÄKYMÄTTÖMÄLLE LASERSÄTEILYLLE ÄLÄ KATSO SÄTEESEEN.

ADVARSEL

USYNLIG LASERSTRÅLNING VED ÅBNING, NÅR SIKKERHEDSBRYDERE ER UDE AF FUNKTION. UNDGÅ UDSAETTELSE FOR STRÅLNING.

VARNING !

OSYNLIG LASERSTRÅLNING NÄR DENNA DEL ÄR ÖPPNAD OCH SPÄRREN ÄR URKOPPLAD. BETRAKTA EJ STRÅLEN. – STRÅLEN ÄR FARLIG.

AL-1000/1010

At the production line, the output power of the scanner unit is adjusted to 0.57 MILLI-WATT PLUS 20 PCTS and is maintained constant by the operation of the Automatic Power Control (APC). Even if the APC circuit fails in operation for some reason, the maximum output power will only be 15 MILLI-WATT 0.1 MICRO-SEC. Giving and accessible emission level of 42 MICRO-WATT which is still-less than the limit of CLASS-1 laser product.

Caution

This product contains a low power laser device. To ensure continued safety do not remove any cove r or attempt to gain acce ss to the inside of the product. Refer all servi ci n g to qu al ified perso nn el.

VAROITUS! LAITTEEN KÄYTTÄMINEN MUULLA KUIN TÄSSÄ KÄYTTÖOHJEESSA MAINITULLA TAVALLA SAATTAA ALTISTAA KÄYTTÄJÄN TURVALLISUUSLUOKAN 1 YLITTÄVÄLLE NÄKYMÄTTÖMÄLLE LASERSÄTEILYLLE.

VARNING - OM APPARATEN ANVÄNDS PÅ ANNAT SÄTT ÄN I DENNA BRUKSANVISNING SPECIFICERATS, KAN ANVÄNDAREN UTSÄTTAS FÖR OSYNLIG LASERSTRÅLNING, SOM ÖVERSKRIDER GRÄNSEN FÖR LASERKLASS 1.

The foregoing is applicable only to the 220V model

230V model and 240V model.

LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT

AL-1000/1010

CONTENTS

[1] GENERAL

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. Target User Copy Volume. . . . . . . . . . . . . . . . . . . . . . . . 1-1

3. Main features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

(1) High-speed laser copying . . . . . . . . . . . . . . . . . . . . 1-1

(2) High-quality digital image. . . . . . . . . . . . . . . . . . . . . 1-1

(3) Substantial copying functions . . . . . . . . . . . . . . . . . 1-1

4. Environmental

(1) Normal operating condition . . . . . . . . . . . . . . . . . . . 1-1

(2) Acceptable condition . . . . . . . . . . . . . . . . . . . . . . . . 1-1

(3) Optional condition . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

(4) Supply storage condition . . . . . . . . . . . . . . . . . . . . . 1-1

[2] SPECIFICATIONS

1. Basic specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2. Operation specification . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3. Copy performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

4. Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

[3] CONSUMABLE PARTS

1. Supply system table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

2. Production control number (lot No.)identification. . . . . . . 3-1

[4] EXTERNAL VIEWS AND INTERNAL STRUCTURES

1. Appearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

2. Operation panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

3. Internal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4. Motors and solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

5. Sensors and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

6. PWB unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

7. Cross sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

[5] UNPACKING AND INSTALLATION

1. A WORD ON COPIER INSTALLATION . . . . . . . . . . . . . 5-1

2. CHECKING PACKED COMPONENTS AND

ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

3. UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

4. REMOVING PROTECTIVE PACKING MATERIAlS . . . . 5-2

5. INSTALLING THE TD CARTRIDGE . . . . . . . . . . . . . . . . 5-2

6. LOADING COPY PAPER (installing the paper tray) . . . . 5-3

7. PLUGGING IN THE COPIER . . . . . . . . . . . . . . . . . . . . . 5-3

[6] PRINTING PROCESS

(1) Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

(2) Outline of print process . . . . . . . . . . . . . . . . . . . . . . 6-2

(3) Actual print process . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

[7] OPERATIONAL DESCRIPTIONS

(1) Outline of operation . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

(2) Scanner section. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

(2) Laser Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Fuser section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Paper feed section and paper transport section. . . . . . . . . . . 7-5

Process unit new drum detection mechanism . . . . . . . . . . . . 7-8

[8] DISASSEMBLY AND ASSEMBLY

1. High voltage section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

2. Operation panel section. . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

3. Optical section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

4. Fusing section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

5. Tray paper feed/transport section . . . . . . . . . . . . . . . . . . 8-7

6. Manual paper feed section. . . . . . . . . . . . . . . . . . . . . . . 8-12

7. Rear frame section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

8. Power section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

[9] ADJUSTMENTS

1. Optical section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

(1) Image distortion adjustment. . . . . . . . . . . . . . . . . . . 9-1

(2) Copy magnification ratio adjustment . . . . . . . . . . . . 9-4

(3) Lens unit attachment reference . . . . . . . . . . . . . . . . 9-6

(4) Image position adjustment. . . . . . . . . . . . . . . . . . . . 9-7

2. Copy density adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

(1) Copy density adjustment timing . . . . . . . . . . . . . . . . 9-8

(2) Note for copy density adjustment. . . . . . . . . . . . . . . 9-8

(3) Necessary tool for copy density adjustment. . . . . . . 9-8

(4) Features of copy density adjustment . . . . . . . . . . . . 9-9

(5) Copy density adjustment procedure. . . . . . . . . . . . . 9-9

3. High voltage adjustment . . . . . . . . . . . . . . . . . . . . . . . . 9-10

(1) Main charger (Grid bias)

(2) DV bias adjustment . . . . . . . . . . . . . . . . . . . . . . . . 9-10

[10] SIMULATION , TROUBLE CODES

1. Entering the simulation mode . . . . . . . . . . . . . . . . . . . . 10-1

2. List of simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

3. Contents of simulations . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

4. Trouble codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11

[11] USER PROGRAMS

Function which can be set with the user program. . . . . . . . . 11-1

Charge the setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

[12] ELECTRICAL SECTION

1. Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

2. Circuit descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3

A. Main PWB(MCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3

(1) CPU signal table . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3

(2) ASIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

(3) Reset circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

(4) Heater lamp control circuit . . . . . . . . . . . . . . . . . . 12-14

(5) Driver circuit (solenoid). . . . . . . . . . . . . . . . . . . . . 12-15

(6) Toner supply motor drive circuit. . . . . . . . . . . . . . 12-15

(7) Main motor drive circuit . . . . . . . . . . . . . . . . . . . . 12-15

(8) Mirror motor circuit . . . . . . . . . . . . . . . . . . . . . . . . 12-16

(9) Power circuit block diagram . . . . . . . . . . . . . . . . . 12-17

(10) CI invertor PWB (circuit). . . . . . . . . . . . . . . . . . . 12-20

(11) CCD PWB operational description. . . . . . . . . . . 12-20

Operation section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-21

[13] CIRCUIT DIAGRAM

AC INTERLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

MCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

OPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8

POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9

ACTUAL WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . 13-10

AL-1000/1010

[1] GENERAL

1. General

This model is a digital personal copier produced with key words of “Comfort able copy, Clear copy, Easy copy” providing high copy performances and copy productivity.

2. Target User Copy Volume: Monthly Average

Copies: 300 ∼ 600 (Max. 800) Prints: 300 ∼ 600 (Max. 800)

3. Main features

(1) High-speed laser copying

● Since warm-up time is zero, copying can be started imme-

diately after the power switch is turned on.

● First-copy time is only 9.6 seconds (normal mode).

● Copying speed is 10 copies/min., which adapts to business

use, allowing improvement of working efficiency.

(2) High-quality digital image

● High-quality image copying at 600 dpi can be performed.

● In addition to the automatic exposure mode, the manual ex-

posure can be adjusted in five steps.

● The photo mode copying function allows clear copying of

delicate halftone original images such as monochrome photos and color photos.

4. Environmental

The environmental conditions for assuring the copy quality and the machine operations are as follows:

(1) Normal operating condition

Temperature:20˚C~25 Humidity:65 ± 5%RH

(2) Acceptable operating condition

Humidity (RH)

85%

60%

20%

10˚C 30˚C 35˚C

(3) Optical condition

Humidity (RH)

90%

(3) Substantial copying functions

● Zoom copying from 50% to 200% in 1% increments can be

performed.

● Continuous copying of maximum 99 sheets can also be per-

formed.

● Toner save mode reduces toner consumption by ap-

proximately 10%.

● User programs allow setting/modification of functions for

customer’s needs.

60%

15%

–25˚C 30˚C 40˚C

(4) Supply storage condition

Humidity (RH)

90%

20%

1-1

–5˚C 45˚C

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)

(mm) Weight Approx. 43.3lbs (19.6kg), TD and drum cartridges included

2. Operation specification

Section, item Details

Paper feed system

Paper size A4, B5, A5 (Landscape) Paper weight 56 – 80g/m Paper feed capacity 250 sheets Kinds Standard paper, specified paper, recycled paper Remark User adjustment of paper guide available Paper size A4, B5, A5, B6, A6 (Landscape) Paper weight 52 – 130g/m Paper feed capacity 50 sheets

Kinds Remark User adjustment of paper guide available

Paper size A4, B5, A5, B6, A6 (Landscape) Paper weight 52 – 130g/m Paper feed capacity 1 sheet

Kinds Remark User adjustment of paper guide available

Paper size 8-1/2″ × 14″, 8-1/2 × 11″, 8-1/2″ × 5-1/2″ (Landscape) Paper weight 15 – 21 lbs. Paper feed capacity 250 sheets Kinds Standard paper, specified paper, recycled paper Remark User adjustment of paper guide available

Paper size Paper weight 14 – 34.5 lbs.

Paper feed capacity 50 sheets Kinds Remark User adjustment of paper guide available

Paper size 8-1/2″ × 14″, 8-1/2 × 11″, 8-1/2″ × 5-1/2″ (Landscape) Paper weight 14 – 34.5 lbs. Paper feed capacity 1 sheet

Kinds Remark User adjustment of paper guide available

Paper feed section

AB system

Inch system

Tray paper feed section

Multi bypass paper feed section

Single bypass paper feed section

Tray paper feed section

Multi bypass paper feed section

Single bypass paper feed section

H293 × W518 × D445mm

1 tray (250 sheet) single bypass

1tray (250 sheet) + multi bypass (50 sheet)

Standard paper, specified paper, recycled paper,

OHP, Label, Postal card

Standard paper, specified paper, recycled paper,

OHP, Label, Postal card

8-1/2″ × 14″, 8-1/2 × 11″, 8-1/2″ × 5-1/2″, 3-1/2″ × 5-

1/2″ (Landscape)

Standard paper, specified paper, recycled paper,

OHP, Label, Postal card

Standard paper, specified paper, recycled paper,

OHP, Label, Postal card

2-1

Section, item Details

Exit way Face down

Paper exit section

Capacity of output tray

Original set Center Registration (left edge) Max. original

Originals

size Original kinds sheet, book Original size

detection Scanning system CCD sensor scanning by lighting lamp scanner CCD sensor Resolution 400 dpi

Type Xenon lamp

Lighting lamp

Voltage 1.5kV

Optical section

Scanning section

Power consumption 11 ± 3W

Writing section

Writing system Writing to OPC drum by the semiconductor laser Laser unit Resolution 600 dpi

Gradation 256 gradations/8bit

Photoconductor

type OPC (30φ) Life 18k

Charging system

Image forming

Charger

Transfer system (+) DC corotron system

Separation system (–) DC corotron system Developing Developing system Cleaning Cleaning system Counter blade system (Counter to rotation)

Fusing system Heat roller system Upper heat roller type Teflon roller

Fusing section

Lower heat roller type Silicon rubber roller

type Halogen lamp heater lamp

Voltage 100V

Power consumption 800W Power source

Voltage 100V, 110V, 120/127V, 230V, 240V

Frequency Common use for 50 and 60Hz

Max. 1000W

Electrical section

Power consumption

Average (during

copying)

Average (stand-by) 70Wh/H *

Pre-heat mode 40Wh/H *

Auto power shut-off

mode

*1) May fluctuate due to environmental conditions and the input voltage.

AL-1000/1010

100 sheets

B4 (10″ × 14″)

None

Saw -tooth charging with a grid, / (–) scorotron

discharge

Dry, 2-component magnetic brush development

system

260Wh/H *

18Wh/H *

2-2

AL-1000/1010

3. Copy performance

Section, item Details

Fixed magnification

Copy magnification

Manual steps (manual, photo)

Copy speed First copy time Tray paper feed

AB system : A4 (Landscape)

B5 (Landscape) Copy speed (CPM)

Inch system 81/2″ × 14″ (Landscape)

8-1/2″ × 11″ (Landscape)

Max. continuous copy quantity

Void

Warm-up time 0 sec. Power save mode

reset time Paper jam recovery

time

ratios Zooming

magnification ratios

Copy speed (CPM)

Void area

Image loss

Manual paper feed

Same size 10

Enlargement 10

Reduction 10

Same size 10

Enlargement 10

Reduction 10

Same size 10

Enlargement 10

Reduction 10

Same size 10

Enlargement 10

Reduction 10

leading edge 1 ∼ 4mm

Trailing edge 4mm or less

Side edge void

area

leading edge

Trailing edge

Side edge void

area

3R + 2E (AB system : 50, 70, 81, 100, 141, 200%)

(Inch system : 50, 64, 78, 129, 100, 200%)

50 ∼ 200% (151 steps in 1% increments)

5 steps

9.6 sec. (Pre-heat mode:16 sec. or below / Auto power-shut-off mode : 23 sec. or below)

Single : 10.0 sec. / Multi : 8.0sec (Pre-heat

mode:16 sec. or below / Auto power-shut-off mode :

23 sec. or below)

3mm or less/per side

same size: 3.0mm or less / Enlarge (200%): 1.5mm

or less / Reduction (50%): 6.0mm or less

same size: 3.0mm or less / Enlarge (200%): 1.5mm

or less / Reduction (50%): 6.0mm or less

same size: 3.0mm or less / Enlarge (200%): 1.5mm

or less / Reduction (50%): 6.0mm or less

0 sec.

2-3

4. Others

Additional

function

Accessories

AL-1000/1010

Section, item Remark

Toner save mode

Pre-heat mode

Auto power shut off mode

Subsidiaries SEC SECL SEEG SUK SCA EX AB EX Inch Tray (Universal) Yes Yes Yes Yes Yes Yes Yes Drum cartridge Yes Yes Yes Yes Yes Yes Yes TD cartridge Yes Yes Yes Yes Yes No* No* AC power cord Yes Yes Yes Yes Yes Yes Yes Tool for corona

cleaning

Operation manual

*Except some

Yes Yes Yes Yes Yes Yes Yes

English1

Can be set or canceled with user

simulation.

Can be set or canceled with user

simulation.

Can be set or canceled with user

simulation.

English1

French

QB/QE:

Multi

language

English2 English2

Yes

Ex.)

English

French

Arabic

English

Spanish

Ex.)

2-4

AL-1000/1010

[3] CONSUMABLE PARTS

1. Supply system table

Common to all destinations

No. Name Content Life Product name Package

Toner/developer cartridge

1 Develop cartridge (Black) × 1

2 Drum cartirdge Drum cartridge 18K AL-100R 5

(Toner: Net weight 220g) (Developer: Net weight 190g)

× 1

(5% document)

AL-100TD 5

2. Production control number(lot No.) identification

〈Developing cartridge〉

Destination (∗)

Indicates production in China.

The end digit of production year

∗:Destination

Division No. Japan option 1 Ex option 2 Japan, same pack 6 Ex, same pack 7

Serial number

(00001-99999)

Production month

January

September October November December

~ 9

0 X Y

〈Drum cartridge〉

The label on the drum cartridge shows the date of production.

Ver. A

The end digit of production year

Ex production 1 Option 2 Same pack 3

Serial number (for each

month) (00001-99999)

Factory

Division No.

Production month

January

September October November December

0 X Y

Production control lavel attachment position

3-1

[4] EXTERNAL VIEWS AND INTERNAL STRUCTURES

1. Appearance

(1)

(2)

AL-1000/1010

(4)

(6)

(5)

(1) Original table (2) Original cover (3) Side cover (4) Operation panel (5) Front cover (6) Paper tray

(7) Side cover open button (8) Paper guides (9) Handle (10) Paper output tray (11) Paper output tray extension (12) Power cord socket (13) Power switch

(7)

(8)

(12)

(3)

(9)

(13)

(10)

(11)

(9)

4-1

AL-1000/1010

2. Operational panel

Exposure mode selector key

(1)

and indicators Copy ratio selector key and

(4)

copy ratio indicators

(1)

(2)

(3)

Light and dark keys and

(2)

exposure indicators

200% 129%

100%

78% 64% 50%

(4)

MAX.

51/281/

100%

81/214

81/211 MIN.

81/211

51/281/

(5)

(6)

x x

ZOOM

(10)

(7)

(11)

(12)

(3) Alarm indicators

(5) Zoom indicator (6) Copy ratio display (%) key

(9)(8)

(13)

∗1

(7) Display (8) ON LINE indicator (9) Power save indicator (10) Zoom keys (11) Copy quantity keys (12) Clear key (13) Print key and ready indicator

∗1

Drum replacement required indicator

When the drum counter reaches 17,000 copies, the indicator lights up. After 1,000 additional copies are made, the indicator starts blinking and machine will hard-stop (after current job) until a new cartridge is installed.

Misfeed indicator

TD cartridge replacement required indicator

When toner density is lower than a specified level, the TONER DEVELOPER CARTRIDGE REPLACEMENT indicator lights up to warn the user. If toner is not added after approximately 10 sheets are copied, the indicator starts blinking and machine starts to supply toner.(Toner Developer cartridg replacement indicator keeps lighting up) If toner density is not back to specific level after two minutes, the READ indicator goes out and Toner Developer indicator starts blinking, and the copier stops.

∗2 ON: Indicates that the machine is in the energy saving (pre-heat) mode.

Blink: Indicates that the machine is in the process of resetting from the energy saving mode or just after supplying the power. OFF: Indicates that resetting from the energy saving mode is completed and that the fusing temperature is in ready state. The combinations of the above display lamps are as follows: (● = ON, ✕ = OFF)

Lamp Immediately after power ON Ready Copying Pre-heat lamp Blink ✕✕ Ready lamp ●●✕ Other lamps ●●●

Copy is started during

resetting from energy

saving mode

Lamp

Energy saving mode (Pre-

heating)

Energy saving mode

(Auto power shut off)

Resetting from energy

saving mode

Pre-heat lamp ●●Blink Blink Ready lamp ●✕●✕ Other lamps ●✕●●

4-2

3. Internal

AL-1000/1010

(1)

(5)

(2)

(6)

(3)

(4)

(8)

(7)

(1) TC cartridge lock release button (2) TD cartridge (3) Drum cartridge (4) Drum cartridge handle (5) Paper feed roller (6) Fusing unit release lever (7) Charger cleaner (8) Transfer charger

4-3

AL-1000/1010

4. Motors and solenoids

(3)

(2)

(4)

(1)

(5)

(7)

(6)

No. Part name Control signal Function,operation

(1) Main motor MM Drives the copier. (2) Mirror motor MRMT Drives the optical mirror base (scanner unit). (3) Toner motor TM Supplies toner. (4) Cooling fan motor VFM Cools the optical section. (5) Resist roller solenoid RRS Resist roller rotation control solenoid (6) Paper feed solenoid CPFS1 Cassette Paper feed solenoid (7) Multi paper feed solenoid MPFS Multi manual pages feed solenoid

4-4

5. Sensors and switches

AL-1000/1010

(1)

(2)

(3)

(4)

(5)

(6)

(9)

(7)

(8)

No. Name Signal Type Function Output

Mirror home position

(1)

sensor

(2) POD sensor POD Transmissions sensor Paper exitdetection “H” at paper pass (3) PPD2 sensor PPD2 Transmission sensor

Cassette detection

(4)

switch Manual feed detection

(5)

switch

(6) PPD1 sensor PPD1 Transmission sensor

(7) Door switch DSW Micro switch

(8) Door switch DSW Micro switch

(9) Drum reset switch DRST Micro switch

MHPS Transmission sensor

CED1 Microswitch

MFD Transmission sensor

Mirror (scanner unit) home position detection

Paper transport detection 2

Cassette installation detection

Manual feed paper detection (single only)

Paper transport detection 1

Door open/close detection (safety switch for 5V)

Door open/close detection (safety switch for 24V)

New drum detection switch

“H” at home position

“L” at paper pass

“H” at cassette insertion

“L” at paper detection

“L” at paper pass

1 or 0V of 5V at door open

1 or 0V of 24V at door open

Instantaneously “H” at insertion of new drum

4-5

AL-1000/1010

6. PWB unit

(1)

(2)

(5)

(8)

(6)

(4)

(3)

(7)

No. Name Function

(1) Exposure lamp invertor PWB Exposure lamp (Xenon lamp) control (2) Main PWB (MCU) Copier control (3) Operation PWB Operation input/display (4) Power PWB AC power input, DC voltage control, High voltage control (5) CCD sensor PWB For image scanning (6) LSU motor PWB For polygon motor drive (7) TCS PWB For toner sensor control (8) LSU PWB For laser control

4-6

7. Cross sectional view

AL-1000/1010

(2)

(1)

(5)

(3)

(4)

(6)

(15)

(14)

(13)

(7) (8)

(9)

(10)

(11)

(12)

No. Part name Function and operation

(1) Scanner unit (2) Exposure lamp Exposure lamp (Xenon lamp) Illuminates original

(3) Lens unit Scans the original image with the lens and the CCD. (4) LSU (Laser unit) Converts the original image signal into laser beams and writes onto the drum. (5) Paper exit roller Roller for paper exit (6) Main charger Provides negative charges evenly to the drum surface. (7) Heat roller Fuses toner on the paper. (Teflon roller) (8) Pressure roller Fuses toner on the paper. (Silicon rubber roller)

(9) Drum Forms images. (10) Transfer unit Transfers images onto the drum. (11) Pickup roller Picks up the manual feed paper. (In multi feed only)

(12)

(13) (14) PS roller unit Takes synchronization between the lead edge and the rear edge of the paper.

(15) Paper feed roller Picks up a sheet of paper from the cassette.

Manual paper feed tray

Manual paper feed roller

Illuminates the original with the copy lamp and passes the reflected light to the lens unit (CCD).

Tray for manual feed paper

Transport the paper from the manual paper feed port.

4-7

AL-1000/1010

[5] UNPACKING AND INSTALLATION

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.

Do not install your copier in areas that are:

● damp, humid, or very dusty

● exposed to direct sunlight

● subject to extreme temperature or humidity changes, e.g.,

near an air conditioner or heater.

Be sure to allow the required space around the machine for servicing and proper ventilation.

8"(20cm)

● poorly ventilated

4" (10cm)

(10cm)

2. CHECKING PACKED COMPONENTS AND ACCESSORIES

Open the carton and check if the following components and accessories are included.

Power cord

Operation manual

Copier

TD cartridge

5-1

Drum cartridge

(installed in copier)

AL-1000/1010

3. UNPACKING

Unpack the copier and carry it to the installation location by holding the handles on both sides of the copier.

4. REMOVING PROTECTIVE PACKING MATERIALS

(1) Remove pieces of tape (a), (b), (c), (d), (e), (f), (g) and (h)

and protective cover (i). Then open the original cover and remove protective materials (j) and (k).

(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.

CAUTION tape

Protective pins

(3) Push gently on both sides of the front cover to open the

cover.

(2) Use a coin (or suitable object) to remove the screw.

Store the screw in the paper tray because it will be used if the copier has to be moved.

5. INSTALLING THE TD CARTRIDGE

(1) Open the side cover while pressing the side cover open

button.

(4) Remove the TD cartridge from the bag. Remove the

protective paper. Hold the cartridge on both sides and shake it horizontally four or five times.

(5) Hold the tab of the protective cover and pull the tab to your

side to remove the cover.

(6) Gently insert the TD cartridge until it locks in place, while

pushing the lock button.

Lock button

5-2

AL-1000/1010

(7) Close the front cover and then the side cover by pressing

the round projections near the side cover open button.

6. LOADING COPY PAPER (installing the paper tray)

(1) Raise the handle of the paper tray and pull the paper tray

out until it stops.

(4) Adjust the paper guides on the paper tray to the copy paper

width and length.Squeeze the lever of paper guide (A) a and slide the guide to match with the width of the paper. Move paper guide (B) to the appropriate slot as marked on the tray.

Paper guide (B)

(5) Fan the copy paper and insert it into the tray. Make sure

the edges go under the corner hooks.

Paper guide (A)

(2) Remove the pressure plate lock. Rotate the pressure plate

lock in the direction of the arrow to remove it while pressing down the pressure plate of the paper tray.

(3) Store the pressure plate lock which has been removed in

step 2 and the screw which has been removed when unpacking (see page 5-2, step 2 of REMOVING PROTECTIVE PACKING MATERIALS) in the front of the paper tray. To store the pressure plate lock, rotate the lock to fix it on the relevant location.

(6) Gently push the paper tray back into the copier.

7. PLUGGING IN THE COPIER

(1) Ensure that the power switch of the copier is in the OFF

position. Insert the attached power cord into the power cord socket at the rear of the copier.

Pressure plate lock

Screw

(2) Plug the other end of the power cord into the nearest outlet.

5-3

[6] Printing process

(1) Functional diagram

An OPC drum is used for the photoconductor. (Structure of the O PC drum layers)

Main charger

AL-1000/1010

OPC layer (20microns thick) Pigment layer (0.2 to 0.3 microns thick) Aluminium drum

(Basic operation cycle)

Laser beam

MG roller

Main high voltage unit

Cleaning blade

Drum

Transfer unit

Resist roller

Semiconductor laser

Focus correction lens

Exposure

To face down tray

Saw tooth

Cleaning blad e

Waste toner box

Paper release Fusing

Heat roller

Heater lamp

Cleaning

Separation

Electrode

Charge

6-1

Drum

Transfer

Transfer charger

Transfer high voltage unit

Developing

Cassette

paper feed

Synchronization

with drum

Toner

Developer

PS roller

Manu al fee d

Pr int process

Paper transport route

AL-1000/1010

(2) Outline of print process

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 surface and a latent image is formed on the drum surface using a laser beam. This latent image forms a visible image on the drum surface when toner is applied. The toner image is then transferred onto the print paper by the transfer corona and fused on the print paper in the fusing section with a combination of heat and pressure.

Step-1: Charge Step-2: Exposure

∗ Latent image is formed on the drum.

Step-3: Developing

Latent image formed on the drum is then changed into visible image with toner.

Step-4: Transfer

The visible image (toner image) on the drum is transfered onto the print paper.

Step-5: Cleaning

Residual toner on the drum surface is removed and collected by the cleaning blade.

Step-6: Optical discharge

Residual charge on the drum surface is removed, by semiconductor laser beam.

Semiconductor laser

Exposure (semiconductor laser)

Drum surface charge sfter the exposure

Non-image area Image area

OPC layer

Pigment layer

Aluminum drum

OPC layer

Pigment layer

Aluminum layer

(3) Actual print process

Step-1: DC charge

A uniform negative charge is applied over the OPC drum surface by the main charging unit. Stable potential is maintained by means of the Scorotron charger. Positive charges are generated in the aluminum layer.

About

DC5.5KV

(–580V/–400V)

Step-3: Developing (DC bias)

A bias potential is applied to the MG roller in the two component magnetic brush developing method, and the toner is charged negative through friction with the carrier. Non-image area of the drum surface charged with negative potential repel the toner, whereas the laser exposed portions where no negative charges exist, attract the toner. As a result, a visible image appears on the drum surface.

: Carrier (Magnetized particle) : Toner (Charge negative by friction) (N) (S) :Permanent magnet (provided in three locations)

Step-2: Exposure (laser beam, lens)

A Laser beam is generated from the semiconductor laser and controlled 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 (corresponding to the print pattern signal). The beam neutralizes the negative charge. An electrostatic latent image is formed on the drum surface.

6-2

–400V ± 8V

MG roller

AL-1000/1010

Non-image area

-600

Drum surface potential

-400

Developing bias

Image area

Residual potential (-50 to -100V)

Charge Exposure D eveloping Transfer

Toner attract potential

Time

Charge

Discharge

Toner is attracted over the shadowed area because of the developing bias.

Step-4: Transfer

The visible image on the drum surface is transferred onto the print paper by applying a positive charge from the transfer corona to the backside of the print paper.

Step-7: Optical discharge (Semiconductor laser)

Before the drum rotation is stopped, the semiconductor laser is 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. When the electrical resistance is reduced, positive charges on the aluminum layer are moved and neutralized with negative charges on the OPC layer.

Semiconductor l aser

Charge by the Scorotron charger Function

The Scorotron charger functions to maintain the surface potential of the drum even at all times which. It is used to control the surface potential regardless of the charge characteristics of the photoconductor.

Basic function

A screen grid is placed between the saw tooth and the photoconductor. A stable voltage is added to the screen grid to maintain the corona current on the photoconductor. As the photoconductor is charged by the saw tooth from the main corona unit, the surface potential increases. This increases the current flowing through the screen grid. When the photoconductor potential nears the grid potential, the current turns to flow to the grid so that the photoconductor potential can be maintained at a stable level.

About DC 5.2kV

Step-5: Separation

Since the print paper is charged positively by the transfer corona, it is discharged by the separation corona. The separation corona is connected to ground.

Step-6: Cleaning

Toner remaining on the drum is removed and collected by the cleaning blade. It is transported to the waste toner collecting section in the cleaning unit by the waste toner transport roller.

Process controlling Function

The print pattern signal is converted into an invisible image by the semiconductor laser using negative to positive (reversible) developing method. Therefore, if the developing bias is added before the drum is charged, toner is attracted onto the drum. If the developing bias is not added when the drum is charged, the carrier is attracted to the drum because of the strong electrostatic force of the drum. To avoid this, the process is controlled by adjusting the drum potential and the grid potential of the Scorotron charger.

Basic function

Voltage added to the screen grid can be selected, high and low. To make it easily understood, the figure below shows voltage transition at the developer unit.

START STOP

Toner at tract potenti al

Low

High

Print potentioal

Developing bias

Drum potential

Time

6-3

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.

3) Once developing bias (–400V) is applied and the photo con-

ductor potential rises to HIGH, toner will not be attracted to the drum.

Stop

The reverse sequence takes place. Retaining developing bias at an abnormal occurrence

Function

The developing bias will be lost if the power supply was removed during print process. In this event, the drum potential slightly abates and the carrier makes deposits on the drum because of strong static power. To prevent this, the machine incorporates a function to retain the developing bias for a certain period and decrease the voltage gradually against possible power loss.

Basic function

Normally, the developing bias voltage is retained for a certain time before the drum comes to a complete stop if the machine should stop before completing the normal print cycle. The developing bias can be added before resuming the operation after an abnormal interruption. Therfore, carrier will not make a deposit on the drum surface.

6-4

[7] OPERATIONAL DESCRIPTIONS

(1) Outline of operation

The outline of operation is described referring to the basic configuration.

(Basic configuration)

AL-1000/1010

Operation

section

Printer section

Scanner section

MCU (Main control/image process section)

LSU (Laser unit) Laser diode, Polygon mirror lens

Laser beam

Process section

Cassette paper

feed section

CCD

Paper exit

Fusing section

Paper transport section

Manual paper

feed section

Outline of copy operation

Setting conditions

1) Set copy conditions such as the copy quantity and the copy density with the operation section, and press the COPY button. The information on copy conditions is sent to the MCU.

Image scanning

2) When the COPY button is pressed, the scanner section starts scanning of images. The light from the copy lamp is reflected by the document and passed through the lens to the CCD.

Photo signal/Electric signal conversion

3) The image is converted into electrical signals by the CCD circuit and passed to the MCU.

Image process

4) The document image signal sent from the CCD circuit is processed under the revised conditions and sent to the LSU (laser unit) as print data.

Electric signal/Photo signal (laser beam) conversion

5) The LSU emits laser beams according to the print data. (Electrical signals are converted into photo signals.)

6) The laser beams are radiated through the polygon mirror and various lenses to the OPC drum.

Printing

7) Electrostatic latent images are formed on the OPC drum according to the laser beams, and the latent images are developed to be visible images (toner images).

8) Meanwhile the paper is fed to the image transfer section in synchronization with the image lead edge.

9) After the transfer of toner images onto the paper, the toner images are fused to the paper by the fusing section. The copied paper is discharged onto the exit tray.

7-1

AL-1000/1010

(2) Scanner section

1) How to scan documents

The scanner has sensors that are arranged in a line. These sensors scan a certain area of a document at a time and deliver outputs sequentially. When the line is finished, the next line is scanned, and this procedure is repeated. The figure below shows the case where the latter two sections of an image which are scanned are shown with solid lines and the former two sections which are being transmitted are shown with dotted lines. The direction of this line is called “main scanning direction,” and the scanning direction “sub scanning direction.” In the figure above, one line is divided into 4 sections. Actually, however, one line is divided into thousands of sections. For scanning, the light receiving element called CCD is used. The basic resolution indicates the scanner capacity. The basic resolution is expressed in dpi (dot/inch) which shows the number of light emitting elements per inch on the document. The basic resolution of this machine is 400dpi. In the sub scanning direction, at the same time, the motor that drives the optical system is controlled to scan the image at the basic resolution.

Main scanning direction

Sub scanning direction

Original

Image data sent to the ICU PWB

5 4 3 2

Sensor scanning area

To MCU PWB

2) Basic structure of scanner section

(1)

(11)

(4)

(7)

1 Copy lamp (Xenon lamp) 2 Reflector (light conversion plate) 3 No. 1 mirror 4 No. 2 mirror 5 No. 3 mirror 6 Lens 7 No. 2/3 mirror unit 8 Copy lamp unit 9 CCD

10 Mirror motor 11 MHPS (Mirror home position sensor)

The scanner unit performs scanning in the digital optical system. The light from the light source (Xenon lamp) is reflected by a document and passed through three mirrors and reduction lenses to the CCD element (image sensor) where images are formed. This system is known as the reduction image sensor system. Photo energy on the CCD element is converted into electrical signals (analog signals). (Photo-electric conversion). The output signals (analog signals) are converted into digital signals (A/D conversion) and passed to the MCU (main control/image process section). The resolution at that time is 400dpi. The mirror unit in the scanner section is driven by the mirror motor. The MHPS is provided to detect the home position of the copy lamp unit.

(2)

(3)

(8)

(6)(5)

(9)

(10)

7-2

AL-1000/1010

(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 images are formed on the OPC drum by the polygon mirror and fθ lens, etc. The laser beams are passed through the collimator lens, the cylindrical lens, the polygon mirror, the fθ lens, and the mirror to form images on the OPC drum in the main scanning direction. The laser emitting PWB is provided with the APC (auto power control) in order to eliminate fluctuations in the laser power. The BF PWB works for measurement of the laser writing start point.

(3)

(5)

No. Component Function

(1) Semiconductor laser Generates laser beams. (2) Collimator lens

Polygon mirror,

(3)

polygon motor BD (Mirror, lens,

(4)

PWB)

(5) fθ lens

(1)(2)

(4)

: Laser beam

path for BF PWB

Converges laser beams in parallel.

Reflects laser beams at a constant rpm.

Detects start timing of laser scanning.

Converges laser beams at a spot on the drum.

Makes the laser scanning speeds at both ends of the drum same as each other. (Refer to the figure below.)

2) Laser beam path

3) Composition

Effective scanning width: 216mm (max.) Resolution: 600dpi Beam diameter: 75um in the main scanning

direction, 80um in the sub scanning direction

Image surface power:

Polygon motor section:

0.20 ±0.03mW (Laser wavelength 780 – 795nm)

Brushless motor 20.787rpm No. of mirror surfaces: 6 surfaces

Makes the laser scanning speeds at both ends of the drum same as each other.

a ≠ b ≠ c

ab c

LENS

d = e = f

def

7-3

AL-1000/1010

Fuser section

1. General description

General block diagram (cross section)

Thermal fuse

Separator pawl

PPD2

B. Separator pawl

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. Thermal control

1. The heater lamp, thermistor, main PWB, DC power supply PWB, and triac within the power supply unit are used to control the temperature in the fuser unit. To prevent against abnormally high temperature in the fuser unit, a thermal breaker and thermal fuse are used for safety purposes.

Heated by the heater lamp. (950W)

Safety device (thermal breaker, thermal fuse)

Triac (in the power supply unit)

The surface temperature of the upper heat roller is sensed by the thermistor.

Level of the thermistor is controlled by the main PWB.

Thermistor

Heat roller

Paper guide

Pressure roller

Top view

Thermal fuse

Heater lamp

Heat roller

Thermistor

Separator pawl

A. Heat roller

A pressure roller is used for the heat roller and a silicone rubber roller is used for the lower heat roller for better toner fusing performance and paper separation.

With the signal from the main PWB, the triac is controlled on and off. (power supply PWB)

2. The surface temperature of the upper heat roller is set to 165˚C ∼ 190˚C. The surface temperature during the power save mode is set to 100˚C.

3. The self-check function comes active when one of the following malfunctions occurs, and an "H" is displayed on the multicopy window.

a. When the heat roller surface temperature rises above

240˚C.

b. When the heat roller surface temperature drops below

100˚C during the copy cycle. c. Open thermistor d. Open thermal fuse e. When the heat roller temperature does not reach 190˚C

within 27 second after supplying the power.

D. Fusing resistor

Fusing resistor

This model is provided with a fusing resistor in the fusing section to improve transfer efficiency. General descriptions are made in the following.

General descriptions

Since the upper heat roller is conductive when copy paper is highly moistured and the distance between the transfer unit and the fusing unit is short, the transfer current leaks through the copy paper, the upper heat roller and the discharging brush.

7-4

Paper feed section and paper transport section

1. Paper transport path and general operations

AL-1000/1010

(2)

(1)

(5)

(3)

(4)

(6)

(7) (8)

(9)

(10)

(11)

(13)

(15)

(1) Scanner unit (6) Main charger (11) Pickup roller (2) Copy lamp (7) Heat roller (12) Manual paper feed tray (3) Lens unit (8) Pressure roller (13) Manual paper feed roller (4) LSU (Laser unit) (9) Drum (14) PS roller unit (5) Paper exit roller (10) Transfer unit (15) Paper feed roller

Paper feed is made in two ways; the tray paper feed and the manual paper feed. The tray is of universal-type, and has the capacity of 250 sheets. The front loading system allow you to install or remove the tray from the front cabinet. The general descriptions on the tray paper feed and the manual paper feed are given below.

(14)

(12)

A. Cassette paper feed operation

1. The figure below shows the positions of the pick-up roller, the paper feed clutch sleeve, and the paper feed latch in the initial state without pressing the COPY button after lighting the ready lamp. The paper feed latch is in contact with the projection of the clutch sleeve.

2. When the COPY button is pressed, the main drive motor starts rotating to drive each drive gear. The pick-up drive gear also is driven at that time. Since, however, the paper feed latch is in contact with the projection of the clutch sleeve, rotation of the drive gear is not transmitted to the pick-up roller, which does not rotate therefore.

PFS

RRS

OFF

7-5

AL-1000/1010

3. After about 0.1 sec from when the main motor start rotating, the tray paper feed solenoid (PFS) turns on at a moment. This disengages the paper feed latch from the projection of the clutch sleeve, transmitting rotation of the pick-up drive gear to the paper feed roller shaft, rotating the pick-up roller to feed the paper.

PFS

RRS

OFF

6. To release the resist roller, the tray paper feed solenoid and the resist solenoid are turned on by the paper start signal to disengage the resist start latch from the clutch sleeve projection, transmitting rotation of the resist drive gear to the resist roller shaft. Thus the paper is transported by the resist roller.

7. After the resist roller starts rotating, the paper is passed through the pre-transfer guide to the transfer section. Images are transferred on the paper, which is separated from the OPC drum by the drum curve and the separation section.

4. After more than half rotation of the pick-up roller, the paper feed latch is brought in contact with the projection of the clutch sleeve, stopping rotation of the pick-up roller.

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 detection of paper by PPD1, the tray paper feed solenoid (PFS) turns on so that the clutch sleeve projection comes into contact with the paper feed latch to stop the pick-up roller. Then the pick-up roller rotates for about 0.15 sec so that the lead edge of the paper is evenly pressed on the resist roller, preventing against skew feeding.

PFS

RRS

OFF

8. The paper separated from the drum is passed through the fusing paper guide, the heat roller (fusing section), POD (paper out detector) to the copy tray.

PFS

RRS

OFF

7-6

AL-1000/1010

B. Manual multi paper feed operation

1. Before paper feed operation, the manual paper feed solenoid (MPFS) is turned OFF as shown in the figure below.

3. When pawl C of the manual paper feed clutch sleeve is hung on the manual feed latch, the manual feed stopper falls and the manual take-up roller rises. At that time, the manual paper feed roller is rotating.

MPFS

2. When the PRINT button is pressed, the manual paper feed solenoid (MPFS) turns on to disengage the manual paper feed latch A from the manual paper feed clutch sleeve A, rotating the manual paper feed roller and the manual takeup roller. At the same time, the manual paper feed stopper opens and the manual take-up roller is pressed to the surface of the paper to start paper feeding.

MPFS

4. The lead edge of the transported paper is pressed on the resist roller by the transport roller. Then the paper is stopped temporarily to make synchronization with the lead edge of the image on the OPC drum. The operations hereinafter are the same as the paper feed operations from the tray. (Refer to A-5 ∼ 8.)

MPFS

7-7

AL-1000/1010

5. The solenoid turns off to close the gate and return to the initial state.

Process unit new drum detection 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.

Gear 20T

Gear 38T

Process detection switch

MPFS

C. Conditions of occurrence of paper misfeed

(1) When the power is turned on:

PPD or POD is ON when the power is turned on.

(2) Copy operation

a. PPD1 jam 1) PPD1 does not turn off within 4 sec

after turning on the resist roller.

b. PPD2 jam 1) PPD2 is off immediately after turning on

the resist roller.

2) PPD2 does not turn off within 1.2 sec after turning off the resist roller.

c. POD jam 1) POD does not turn on within 2.9 sec

after turning on the resist roller.

2) POD does not turn off within 1.5 sec ∼

2.7 sec after turning off PPD2.

2. When the detection gear 38Y turns one rotation, there is no gear any more and it stops. The latch section of the 38T gear is latched and fixed with the projection of the process cover.

Gear notch

Gear pawl

Projection

Gear notch

7-8

Projection

Gear pawl

AL-1000/1010

[8] DISASSEMBLY AND ASSEMBLY

Before disassembly, be sure to disconnect the power cord for safety. The disassembly and assembly procedures are described for the following sections:

1. High voltage section

2. Operation panel section

3. Optical section

4. Fusing section

5. Tray paper feed/transport section

6. Manual paper feed section

7. Rear frame section

8. Power section

1. High voltage section

A. List

No. Part name Ref. page

1 Transfer charger unit 8-1 2 Charger wire 8-1

B. Disassembly procedure

(1) Press the side cover open/close button and open the side

cover.

(2) Push up the lock pawls (2 positions) of the side cover, and

remove the transfer charger.

Lock pawl rear

Transfer charger

Lock pawl front

C. Assembly procedure

For assembly, reverse the disassembly procedure.

8-1

AL-1000/1010

D. Charger wire cleaning

(1) Remove the charger cleaner from the manual paper feed

unit.

(2) Set the charger cleaner to the transfer unit, and move it

reciprocally a few times in the arrow direction shown in the figure below.

E. Charger wire replacement

(1) Remove the TC cover and remove the screw. (2) Remove the spring and remove the charger wire. (3) Install a new charger wire by reversing the procedures (1)

and (2). At that time, be careful of the following items.

● The rest of the charger wire must be within 1.5mm.

● The spring hook section (charger wire winding section)

must be in the range of the projection section.

● Be careful not to twist the charger wire.

Charger wire

1mm

Protrusion

1.5mm

8-2

AL-1000/1010

2. Operation panel section

A. List

No. Part name Ref. page

1 Operation panel unit 8-3 2 Operation PWB 8-3

B. Disassembly procedure

(1) Remove the screws (4 pcs.), the harness, and the opera-

tion panel unit.

C. Assembly procedure

For assembly, reverse the disassembly procedure

3. Optical section

A. List

NO. Part name Ref. page

1 Copy lamp unit 8-4 2 Copy lamp 8-4 3 Lens unit 8-4

B. Disassembly procedure

(1) Remove the parts as shown below.

(2) Remove the screws (3 pcs.) and the PWB holder. (3) Remove the screws (3 pcs.) and the operation PWB.

Hook

10)

Note that there are 13 pawls

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AL-1000/1010

(2) Remove the screws (2pcs.), and remove the copy lamp

unit from the mirror base drive wire.

(5) Remove the screws (2 pcs.), the harness, and the optical

unit.

When installing the lens unit, refer to “9-7. Lens unit installation reference.”

(3) Pull the copy lamp unit toward you to remove the harness.

(4) Remove the screw (4 pc) and remove the cover.

C. Assembly procedure

Basically reverse the disassembly procedure. The mirror base drive wire and the lens drive wire stretching methods are described below. a. Mirror base drive wire stretching

1. Hook the metal fixture of the mirror base drive wire on the projection of the optical base plate.

2. Pass the wire through the external groove of the double pulley. (At that time, check that No. 2/3 mirror unit is in contact with the mirror base positioning plate.)

3. Hold so that the winding pulley groove is up, and wind the mirror base drive wire 9 turns.

4. Put the 8th turn of the mirror base drive wire in the winding pulley groove and fix with a screw.

5. Pass the wire under Mo. 2/3 mirror unit plate and wind it around pulley A.

6. Pass the wire through the internal groove of the double pulley, and pass through pulley B.

7. Hook the spring hook on the optical base plate.

Wind closely

8-4

After installing the mirror base drive wire, be sure to perform main scanning direction image distortion adjustment.

AL-1000/1010

4. Fusing section

A. List

No. Part name Ref. page

1 Thermistor 8-5 2 PPD2 sensor 8-5 3 Heater lamp 8-6 4 Pressure roller 8-5 5 Heat roller 8-5

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.

(4) Remove the screw and remove the U-turn guide.

Pressure roller section disassembly

(5) Remove the three screws, remove the fusing cover lower

on the right side, and open the heat roller section.

(3) Cut the binding band, remove the screw, and remove the

thermistor.

(6) Remove the screw and remove the PPD2 sensor.

PPD2 sensor

Thermistor

8-5

AL-1000/1010

(7) Remove the plate spring on the right and remove the

heater lamp.

Hearter lamp

(10) Remove the pressure release levers on the right and the

left sides.

(11) Remove the pressure roller, the pressure bearing, and the

pring.

Note: Apply grease to the sections specified with ✽.

✽

(8) Remove the spring and remove the separation pawls (3

pcs.).

(9) Remove the E-ring and remove the reverse gate.

Pressure roller

✽

Heat roller disassembly (Continued from procedure (4).)

(5) Remove screws, remove the fusing cover, and open the

heat roller section.

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AL-1000/1010

(6) Remove the C-ring and the fusing bearing, and remove the

heat roller.

(7) Remove the parts from the heat roller.

Note: Apply grease to the sections specified with ✽.

✽

Heat roller

5. Tray paper feed/transport section

A. List

No. Part name Ref. page

1 PPD1 sensor PWB 8-11 2 LSU unit 8-10 3 Intermediate frame unit 8-10 4 Paper feed roller 8-11

B. Disassembly procedure

(1) Remove six connectors and screws of the main PWB, and

lift the optical unit and the main PWB to remove.

✽

(8) Remove two screws and remove the thermo unit.

(2) Remove the PWB insulation mylar and remove the paper

transport detection sensor (PPD2).

C. Assembly procedure

For assembly, reverse the disassembly procedure.

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AL-1000/1010

(3) Remove two screws and remove the toner motor.

(4) Remove two springs and open the intermediate frame unit.

(5) Remove the pulleys on the both sides and remove the

paper exit roller.

(6) Pull out the paper exit roller knob and remove the belt.

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AL-1000/1010

(7) Release the belt pulley (a) lock and remove the belt pulley

bearing.

(9) Remove the harness guide.

(10) Remove five screws and remove the main drive plate and

the belt.

(8) Remove the paper exit roller.

CAUTION:Attach

the gears securely

8-9

AL-1000/1010

(11) Remove the parts as shown below, and remove the pres-

sure release solenoid and the paper feed solenoid.

(13) Remove two screws and remove the fusing connector. (14) Remove five screws and the connector, and lift the inter-

mediate frame unit to remove.

(12) Remove six screws and remove the LSU unit.

(15) Remove the screw and the E-ring, and remove the PS

semi-circular earth plate and the PS roller unit.

(16) Remove the E-ring and remove the spring clutch from the

PS roller unit.

PS roller unit

PS semi-circuler

PS semi-circuler earth plate

earth plate

8-10

AL-1000/1010

(17) Remove three screws and remove the TC front paper

guide.

(18) Remove the screw and the connector, and remove the

PPD1 sensor PWB.

(19) Remove two E-rings and remove the paper feed roller. (20) Remove three E-rings and remove the clutch unit.

Back

Clutch unit

Paper feed roller

Front

C. Assembly procedure

For assembly, reverse the disassembly procedure.

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AL-1000/1010

6. Manual paper feed section

A. List

No. Part name Ref. page

1 Manual transport roller 8-15 2 Cassette detection switch 8-13 3 PPD1 sensor PWB 8-13 4 Side door detection unit 8-12

B. Disassembly procedure Single unit

(1) Remove the screw and remove the single upper cover.

(2) Remove the screw and remove the side door detection

unit.

Back

(3) Remove three screws and remove the single manual feed

upper frame.

Wire treatment

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AL-1000/1010

(4) Remove the PPD1 sensor PWB.

(6) Remove the cassette detection switch.

Wire treatment

(5) Remove the E-ring and remove the manual paper feed

transport roller.

Wire treatment

(7) Remove the multi cover.

Multi cover

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AL-1000/1010

Multi unit

(1) Remove the screw and remove the multi upper cover.

(3) Remove three screws and remove the multi paper feed

upper frame.

(2) Remove the screw and remove the side door detection

unit.

Orange

Red

Back

Wire treatment

(4) Remove two screws and remove the multi feed bracket unit

from the multi paper feed upper frame.

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AL-1000/1010

(5) Remove three E-rings and remove the manual paper feed

roller B9.

(7) Cut the binding band and remove the multi paper feed

solenoid.

Multi paper feed solnoid

(6) Remove the pick-up roller.

C. Assembly procedure

For assembly, reverse the disassembly procedure.

D. Pressure plate holder attachment

(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

8-15

AL-1000/1010

7. Rear frame section

A. List

No. Part name Ref. page

1 Mirror motor 8-16 2 Main motor 8-16 3 Exhaust fan motor 8-16

B. Disassembly procedure

(1) Remove three screws and remove the rear cabinet.

(3) Remove two screws and one harness, and remove the

main motor.

(2) Remove two screws, the harness, and the mirror motor.

(4) Remove two screws and one connector, and remove the

exhaust fan motor.

C. Assembly procedure

For assembly, reverse the disassembly procedure.

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AL-1000/1010

8. Power section

A. List

No. Part name Ref. page

1 Power PWB 8-17

B. Disassembly procedure

(1) Remove two screws and one connector, and remove the

power PWB.

C. Assembly procedure

For assembly, reverse the disassembly procedure.

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AL-1000/1010

[9] Adjustment

1. Optical section

(1) Image distortion adjustment

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. 2/3 mirror unit).

a. Horizontal image distortion adjustment

I. Summary

Parallelism of mirrors can be made by installing the copy lamp unit and No. 2/3 mirror unit to the reference position. However, it must be checked by making a copy, and must be adjusted if necessary.

II. Cases when the adjustment is required

1) When the copy lamp unit and No.2/3 mirror unit are disassembled or their part is replaced.

2) When the copy lamp unit and No.2/3 mirror unit drive section is disassembled or its part is replaced.

3) When the copy image is distorted as shown below:

IV. Adjustment procedure

1) Remove the right cabinet (manual paper feed unit), the document reference plate.

2) Remove the document glass.

3) Loosen the fixing screw of the copy lamp unit wire.

Document

Copy A

Copy B

III. Necessary tools

● Screwdriver (+)

● Hex wrench

● Scale

● Test chart for distortion adjustment (Make a chart shown

below by yourself.) Draw a rectangle on a paper (B4 or 8 1/2″ × 14″) as shown below. Be sure to make four right angles.

L = 10mm

4) Manually turn the copy lamp unit/No.2/3 mirror unit drive gear to bring No.2/3 mirror unit into contact with No.2/3 mirror unit positioning plate. When No.2/3 mirror unit makes contact with No.2/3 mirror unit positioning plate in the rear frame side simultaneously, the mechanical parallelism of No.2/3 mirror unit is proper. If one side of No.2/3 mirror unit makes contact with No.2/3 mirror unit positioning plate and the other side does not, the parallelism is improper. If the parallelism is improper, perform the procedure of step 5).

9-1

5) Loosen the copy lamp unit/No.2/3 mirror unit drive pulley setscrew in the side where No.2/3 mirror unit does not make contact with No.2/3 mirror unit positioning plate.

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.

8) With No.2/3 mirror unit positioning plate in contact with No.2/3 mirror unit, bring the copy lamp unit into contact with the right frame and fix the copy lamp unit to the drive wire. Procedures 1) to 8) are for adjustment of mechanical horizontal parallelism. The copy lamp unit and No.2/3 mirror are fixed to the specified positions and the mechanical horizontal parallelism of No.2/3 mirror is adjusted. Then the optical horizontal parallelism must be adjusted in the following procedures.

Copy lamp unit projection

Set screw

Scanner unit drive pulley

6) Without moving the copy lamp unit/No.2/3 mirror unit drive pulley shaft, manually turn the copy lamp unit/No.2/3 mirror unit drive pulley in the same direction of the loosened setscrew. When it makes contact with No.2/3 mirror unit positioning plate, tighten and fix the setscrew.

9) Set the image distortion check chart on the document table, and make a reduction copy (75%) on an A4 or 11″ × 8 1/2″ paper with the document cover open.

50mm

9-2

Image distortion check chart

AL-1000/1010

10) Check the horizontal image distortion. If LL = LR, there is no horizontal distortion

LL and LR: Distance between the copy image horizontal line and

the edge of the black

background.

Black background

11) If LL is not equal to LR, perform the following proce-

dure. Loosen the setscrew of the copy lamp unit/No.2/3 mirror unit drive pulley in the front or the rear frame.

Set screw

b. Vertical image distortion adjustment

I. Summary

In this adjustment, the left and right balance is adjusted by changing the left and right balance of the No. 2 scanner unit frame on the front frame side.

II. Note

● Horizontal image distortion adjustment

III. Cases when the adjustment is required

1) When the copy lamp unit/No.2/3 mirror unit drive section is disassembled or its part is replaced.

2) When the copy image is distorted as follows:

Document

Copy C

IV. Necessary tools

● Screwdriver (+)

● Screwdriver (–)

● Scale

● Test chart for distortion adjustment (Make by yourself.)

Draw a rectangle on A4 or 8 1/2″ × 11″ paper as shown below: Be sure to make four right angles.

Copy D

Scanner unit drive pulley

12) Without moving the copy lamp unit/No.2/3 mirror unit drive pulley shaft, manually turn the copy lamp unit/No.2/3 mirror unit drive pulley whose setscrew was loosened, and adjust the parallelism of copy lamp unit/No.2/3 mirror unit.

L = 10mm

V. Adjustment procedure

1) Set the test chart for image distortion adjustment on the document glass, and make a normal copy on a paper of A4 or 8 1/2″ × 11″.

2) Check image distortion in the right and the left sides. If the both vertical lines are in parallel with each other, the right-left distortion balance is proper. (However, there may be some distortion.)

2) If all the four angles are right angles, there in no distor-

tion and the following procedures are not required.

Greater distortion

Smaller distortion

13) Tighten the set screw of the copy lamp unit/No.2/3 mirror unit drive pulley.

14) Check the image distortion in the same manner as step

10). Repeat procedures 11) to 14) until horizontal image distortion is eliminated.

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AL-1000/1010

3) If the right-left distortion balance is improper, loosen the fixing screw of No.2/3 mirror unit rail to change and adjust the right-left balance of No.2/3 mirror unit rail.

(Note) If the distortion in the lead edge side (when viewed in the

paper transport direction) is greater, change the height of the left rail of No.2/3 mirror unit. If the distortion in the rear edge side (when viewed in the paper transport direction) is greater, change the height of the right rail of No.2/3 mirror unit.

Change the height of the right side of the rail.

a. Outline

The main scanning (front/rear) direction magnification ratio adjustment is made automatically or manually.

Automatic adjustment: The width of the reference line marked on the shading correction plate is scanned to perform the main scanning (front/rear) direction magnification ratio adjustment automatically.

Manual adjustment: The adjustment is made by manual key operations. (In either of the automatic and manual adjustments, the zoom data register set value is changed for adjustment.)

The magnification ratio in the sub scanning direction is adjusted by changing the mirror base (scanner) scanning speed.

b. Main scanning direction magnification ratio ad-

justment

I. Note

Before performing this adjustment, the following adjustments must have been completed. If not, this adjustment cannot be performed properly.

● Image distortion adjustment

● The lens unit must be installed in the reference position.

II. Cases when the adjustment is required

1) When the lens and the mirror unit are disassembled or the part is replaced.

2) When the copy lamp unit/No.2/3 mirror unit drive section is disassembled or the part is replaced.

3) When the main PWB is replaced.

4) When the EEPROM in the main PWB is replaced.

5) When “U2” trouble occurs.

6) When the copy image distortion adjustment is performed.

Change the height of the left side of the rail.

4) Make a copy to check the vertical image distortion. If the four angles are right angles, the adjustment is completed.

(2) Copy magnification ratio adjustment

The copy magnification ratio must be adjusted in the main scanning direction and in the sub scanning direction. To adjust, use SIM 48-1.

III. Necessary tools

● Screwdriver (+)

● Scale

IV. Adjustment procedure

1) Set the scale vertically on the document table. (Use a long scale for precise adjustment.)

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AL-1000/1010

2) Set the copy magnification ratio to 100%.

3) Make a copy on A4 or 81⁄2″ × 11″ paper.

4) Measure the length of the copied scale image.

(When a 100mm scale is used as the original.)

Paper feed direction

mm 1/2mm

Reference

10 20

6) Check that the copy magnification ratio is within the specified range. If it is not within the specified range, perform the following procedures.

7) Execute SIM 48-1 to select the main scanning direction copy magnification ratio adjustment mode. To select the adjustment mode, use the copy mode select key.

In the case of the automatic adjustment, when the PRINT switch is pressed, the mirror base unit moves to the white plate for shading to scan the width of the reference line, calculating the correction value and displaying and storing this value. After execution of the automatic adjustment, go out from the simulation mode and make a copy to check the magnification ratio. If the magnification ratio is not in the specified range (100 ±1.0%), manually adjust as follows.

Adjustment mode Lighting lamp

Main scanning direction auto copy magnification ratio adjustment

Main scanning direction manual copy magnification ratio adjustment

Sub scanning direction copy magnification ratio adjustment

Auto exposure lamp ON

Manual exposure lamp ON

Photo exposure lamp ON

5) Calculate the main scanning direction magnification ratio. Main scanning direction magnification ratio

Copy image dimensions

Original dimension

100 110 120 130

110

100

Comparison point

JAPAN

120 130

140

× 100 (%)

Original (Scale)

HARDDENCD STAINLESS

150

Shizuoka

HARDDENCD STAINLESS

150

Shizuoka

Copy

110

must have been completed. If not, this adjustment cannot be performed properly.

● Image distortion adjustment

● Must be installed to the lens unit reference position.

II. Cases when the adjustment is required

1) When the lens and the mirror unit are disassembled or the part is replaced.

2) When the scanner unit drive section is disassembled or the part is replaced.

3) When the main PWB is replaced.

4) When the EEPROM in the main PWB is replaced.

5) When “U2” trouble occurs.

6) When the copy image distortion adjustment is performed.

III. Necessary tools

● Screwdriver (+)

● Scale

IV. Adjustment procedure

1) Set the scale on the document table as shown below. (Use a long scale for precise adjustment.)

8) Set the adjustment mode to Manual with the copy mode select key.

9) Enter the new set value of main scanning direction copy magnification ratio with the copy quantity set key, and press the COPY button.

10) Change the set value and repeat the adjustment until

the ratio is within the speoified range. When the set value is changed by 1, the magnification ration is changed by 0.1%.

c. Sub scanning direction copy magnification ratio

I. Note

Before performing this adjustment, the following adjustments

9-5

2) Set the copy magnification ratio to 100%.

3) Make a copy on A4 or 8

⁄2″ × 11″ paper.

mm 1/2mm

10 20

100

110 120 13 0

JAPAN

110

140

Original (Scale)

HARDDENCD STAINLESS

150

Shizuoka

AL-1000/1010

mm 1/2mm

Reference

100

Comparison point

4) Measure the length of the copied scale image.

5) Calculate the sub scanning direction copy magnification ratio. Sub scanning direction copy magnification ratio

Copy image dimension

Original dimension

× 100 (%)

6) Check that the actual copy magnification ratio is within the specified range. (100 ± 1.0%). If it is not within the specified range, perform the following procedures.

7) Execute SIM 48-1 to select the sub scanning direction copy magnification ratio adjustment mode. To select the adjustment mode, use the copy mode select key. (Photo exposure lamp ON)

8) Enter the new set value of sub scanning direction copy magnification ratio with the copy quantity set key, and press the COPY button.

Repeat procedures 1) — 8) until the sub scanning direction actual copy magnification ratio in 100% copying is within the specified range.

When the set value is changed by 1, the magnification ration is changed by 0.1%.

110 120

Paper feed direction

JAPAN

130

140

150

Copy

HARDDENCD STAINLESS

Shizuoka

(3) Lens unit attachment reference

Attach the lens unit so that the lens unit number on the lens adjustment plate is aligned with the scribe line on the base plate.

Lens unit number

(–) direction Reference line (0) (+) direction

Example: Lens unit number –2.8

Attach the lens unit at 2 scales in the paper exit direction from the reference line.

Note: Never touch the other screws than the unit attach-

ment screw. The lens unit is supplied only in a whole unit.

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AL-1000/1010

(4) Image position adjustment

There are following five kinds of image position adjustments, which are made by laser control except for the image scan start position adjustment. For the adjustments, SIM 50 – 01 and SIM 50 – 10 are used.

No. Adjustment item Simulation

1 Print start position 50 – 01 2 Image lead edge void amount 50 – 01 3 Image scan start position 50 – 01 4 Image rear edge void amount 50 – 01 5 Center offset 50 – 10

To select the adjustment mode with SIM 50 – 01, use the copy density select key. The relationship between the adjustment modes and the lighting lamps are as shown in the table below.

Adjustment mode Lighting lamp

Print start position Auto (AE) lamp

Image lead edge void amount Manual (TEXT) lamp

Image scan start position Photo lamp

Image rear edge void amount

To select the adjustment mode with SIM 50 – 10, use the copy mode select key.

Auto, Manual, Photo lamps

4) Measure the image loss amount (R mm) of the scale image. Set C = 10 × R (mm). (Example: Set the value of C to 30.) When the value of C is increased by 10, the image loss is decreased by 1mm. (Default: 50)

5) Measure the distance (H mm) between the paper lead edge

and the image print start position. Set A = 10 × H (mm). (Example: Set the value of A to 50.) When the value of A is increased by 10, the image lead edge is shifted to the paper lead edge by 1mm. (Default: 50)

6) Set the lead edge void amount to B = 50 (2.5mm). When the value of B is increased by 10, the void amount is increased by about 1mm. For 25 or less, however, the void amount becomes zero. (Default: 50)

(Example)

Distance between paper lead edge and image: H = 5mm

Image loss: R = 3mm

5mm

10mm

The relationship between the adjustment modes and the lighting lamps are as shown in the table below.

Machine with the multi manual paper feed unit

Adjustment mode Lighting lamp

Print center offset (cassette) Auto, Cassette

Print center offset (manual feed) Auto, Manual

Document center offset Auto, Manual

Machine with the single manual paper feed unit

Print center offset (cassette) Auto, Cassette

Print center offset (manual feed) Auto

Document center offset Auto, Manual

1. Lead edge adjustment

1) Set a scale to the center of the paper lead edge guide as shown below, and cover it with B4 or 8 1/2″ × 14″ paper.

2. Image rear edge void amount adjustment

1) Set a scale to the rear edge section of A4 or 11″ × 8 1/2″ paper size as shown in the figure below, and cover it with B4 or 8 1/2″ × 14″ paper.

B4 or 8 1/2″ × 14″ paper

A4 size rear edge

2) Execute SIM 50 – 01 to select the image rear edge void amount adjustment mode. The set adjustment value is displayed on the copy quantity display.

3) Make a copy and measure the void amount of image rear edge.

Void amount (Standard value: 2 – 3mm)

2) Execute SIM 50 – 01

3) Set the print start position (AE lamp ON) (A), the lead edge void amount (TEXT lamp ON) (B), and the scan start position (PHOTO lamp ON) (C) to 0, and make a copy of a scale at 100%.

Scale image

Paper rear edge

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AL-1000/1010

4) If the measurement value is out of the specified range, change the set value and repeat the adjustment procedure. The default value is 50.

3. Center offset adjustment

1) Set the self-made test chart for the center position adjustment so that its center line is aligned with the center mark of the document guide.

● Test chart for the center position adjustment Draw a line at the center of A4 or 8 1/2″ × 11″ paper in the paper transport direction.

Document guide

Center

Copy paper (A4 or 8 1/2″ × 11″)

2) Execute SIM 50 – 10 to select the print center offset (cassette paper feed) adjustment mode. The set adjustment value is displayed on the copy quantity display.

3) Make a copy and check that the copied center line is properly positioned. The standard value is 0 ± 2mm from the paper center.

2. Copy density adjustment

(1) Copy density adjustment timing

The copy density adjustment must be performed in the following cases:

● When maintenance is performed.

● When the developing bias/grid bias voltage is adjusted.

● When the optical section is cleaned.

● When a part in the optical section is replaced.

● When the optical section is disassembled.

● When the OPC drum is replaced.

● When the main control PWB is replaced.

● When the EEPROM on the main control PWB is replaced.

● When the memory trouble (U2) occurs.

(2) Note for copy density adjustment

1) Arrangement before execution of the copy density adjustment

● Clean the optical section.

● Clean or replace the charger wire.

● Check that the voltage at the high voltage section and the

developing bias voltage are in the specified range.

(3) Necessary tool for copy density adjustment

● One of the following test charts:

UKOG-0162FCZZ, UKOG-0089CSZZ, KODAK GRAY SCALE

● B4 (14″ × 8 1/2″) white paper

● The user program AE setting should be “3.”

1 10

23456789

(Copy A)

(Copy B)

(Paper feed direction)

2.0mm or less

Shift

2.0mm or less

Shift

Copy image Copy paper

folding line

Copy image Copy paper

folding line

4) If the measured value is out of the specified range, change the set value and repeat the adjustment procedure. When the set value is increased by 1, the copy image is shifted by 0.1mm toward the rear frame.

● For the manual paper feed, change the manual paper feed adjustment mode and perform the similar procedures.

● Since the document center offset is automatically adjusted by the CCD which scan the reference lines (F/R) on the back of document guide, there is no need to adjust manually.

Test chart comparison table

UKOG0162FCZZ

12345678910W

DENSITY No. UKOG-

0089CSZZ

0.1 0.2 0.3 0.5 1.9 0

DENSITY No. KODAK

GRAY

123419A

SCALE

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AL-1000/1010

(4) Features of copy density adjustment

For the copy density adjustment, the image data shift function provided in the image process LSI is used.

List of the adjustment modes

Auto Mode Brightness 1 step only Manual Mode

Photo Mode Manual T/S

mode T/S Auto

mode

Brightness 5 steps. Adjustment of only the center brightness is made.

Brightness 1 step only

(5) Copy density adjustment procedure

Use SIM 46-01 to set the copy density for each copy mode. For selection of modes, use the copy mode select key.

A. Test chart (UKOG-0162FCZZ) setting

1) Place the test chart so that its edge is aligned with the A4 (Letter) reference line on the document table. Then place a B4 (14″ × 8 1/2″) white paper on the test chart and close the document cover.

White paper

B. Perform the adjustment in each mode.

(1) Execute SIM 46-1. (2) Select the mode to be adjusted with the exposure mode

select key. Set the exposure level to 3 for all adjustment. (Except for the auto mode.)

(1)

Adjustment

mode

Auto mode Auto lamp ON —

Manual

mode

Photo mode Photo lamp ON 3

Manual T/S

mode

Auto T/S

mode

(2)

(1) Mode select key/display

lamp

(2) Exposure level select

key/display lamp

Exposure mode

display lamp

Ex-

posure

level

Manual lamp ON 3

Manual

lamp/Photo lamp

Auto lamp/Photo

lamp ON

Sharp gray chart

adjustment level “3” is slightly

copied. “3” is slightly

copied. “4” is slightly

copied.

Test chart

(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

1 10

23456789

Non toner

save mode

Not copied.

1 10

Slightly copied.

23456789

Toner save

mode

Not copied.

Slightly copied.

(When too bright): Decrease the value displayed on the

copy quantity display.

(When too dark): Increase the value displayed on the copy

quantity display.

* The value can be set in the range of 1 — 99.

9-9

AL-1000/1010

3. High voltage adjustment

(1) Main charger (Grid bias)

Note:

● Use a digital multi meter with internal resistance of 10MΩ or more measurement.

● After adjusting the grid LOW output, adjust the HIGH output. Do not reverse the sequence.

Procedures

1. Set the digital multi meter range to DC700V.

2. Set the positive side of the test rod to the connector CN11-3 (GRID) of high voltage section of the power PWB and set the negative side to the frame ground (radiating plate).

3. Execute SIM 8-3. (The main charger output is supplied for 30 sec in the grid voltage LOW output mode.)

4. Adjust the control volume (VR-141) so that the output voltage is –400 ±20V.

5. Execute SIM 8-2. (The main charger output is supplied for 30 sec in the grid voltage HIGH output mode.)

6. Adjust the control volume (VR-142) so that the output voltage is 580 ±10V.

(2) DV bias adjustment

Note:

● A digital multi meter with internal resistance of 1GΩ must be use for correct adjustment.

Procedures

1. Set the digital multi meter range to DC500V.

2. Set the positive side of the test rod to the connector CN-101 (DV BIAS) and set the negative side to the connector CN10-2 (FG).

3. Execute SIM 8-1. (The developing bias is outputted for 30 sec.)

4. Adjust the control volume (VR-121) so that the output voltage is –400 ±5V.

9-10

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

The current set adjustment value and the counter value are displayed on the COPY QUANTITY displayed Sensor check, etc. are displayed by the

alarm lamps, etc.

To change the current set values, enter with the COPY QUANTITY key.

10th digit:

1st digit: Count up of values:

COPY QUANTITY key Count down of values:

Zoom key + COPY QUANTITY key

The entered value is displayed on the COPY QUANTITY display.

Press the COPY key.

Is there a sub code ?

Press the COPY key.

Is it the

simulation for

operation

check?

YES

Preform the operation according to the simulation number.

Is another

simulation to be

performed ?

Press the clear key.

All displays on the operation panel go off, and the machine enters the ready state for entering the main code.

YES

Press the COPY key.

The COPY QUANTITY display blinks to indicate "00" and the machine enters the ready state for sub code input.

Enter the sub code with the COPY QUANTITY key.

10th digit: 1st digit: Count up of values:

COPY QUANTITY key Count down of values: Zoom key + COPY QUANTITY key

Press the COPY key.

Is the main code the same ?

Is the sub code displayed ?

YES

Press the clear key.

The COPY QUANTITY display blinks to indicate the previously set sub enters the ready7 state for sub code input. code, and the machine

YES

Press the clear key.

Enter the new main code.

The main code is displayed on the COPY QUANTITY display.

Start

Press the clear key.

Within 3sec

Press the exposure mode selector key.

Within 3sec

Press the clear key.

Within 3sec

Press the exposure mode selector key.

All displays on the operation panel go off, and the machine enters he ready state for entering he main code.

Enter the main code with the COPY QUANTITY key.

10th digit: 1st digit: Count up of values:

COPY QUANTITY key Count down of values: Zoom key + COPY QUANTITY key

The main code is displayed on the COPY QUANTITY display.

The entered value is registered.

Press the clear key.

End

10-1

2. List of simulation

Main code Sub code Content

1 1 Scanner unit operation check 5 1 Operation panel display lamps operation check

2 Fusing lamp and cooling fan operation check 3 Copy lamp operation check

6 1 Paper feed solenoids (CPFS1, CPFS2, MPFS) operation check

2 Resist solenoid (RRS) operation check

7 1 Warm-up time display and aging with JAM

6 Intermittent aging

8 1 Developing bias check

2 Main charger (Grid high output mode) check 3 Grid voltage (Grid low output mode) check

6 Transfer charger check 10 - Toner motor operation check 14 - Cancel of trouble other than U2 16 - Cancel of U2 trouble 22 5 Total counter value display

12 Drum counter value display 14 P-ROM version display 21 Scanner counter value display

24 7 Drum counter clear

13 Scanner counter clear

25 1 Main motor operation check

10 Polygon motor operation check

26 1 Manual paper feed section setting

6 Destination setting

7 Machine conditions check

20 Rear edge void setting 30 CE mark application control ON/OFF setting 38 Drum life over stop cancel 39 Memory capacity setting 40 Polygon motor OFF time setting

42 Transfer ON timing control (Setting the time to transfer ON) 30 1 Paper sensor status display 43 1 Fusing temperature setting

4 Multi copy fusing temperature setting 46 1 Copy density adjustment 48 1 Front/rear scanning direction magnification ratio adjustment 50 1 Lead edge position and paper lead edge/rear edge void adjustment

10 Center offset adjustment 51 2 Resist amount adjustment 61 3 Polygon motor (HSYNC output) check 63 1 Shading check 64 1 Self print by engine only (1 by 2 mode)

AL-1000/1010

(*)In the simulation mode (except for the aging mode), when the 1-digit up key is pressed while pressing the % key, it serves as the 1-digit down key. When 10-digit up key is pressed while pressing the % key, it serves as the 10-digit down key.

10-2

AL-1000/1010

3. Contents of simulations

Main code Sub code Contents

1 1 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. The copy magnification ratio can be arbitrarily set with the magnification ratio select key/zoom key.

5 1 Operation panel display lamps operation check

(Operation/Procedure) When the START key is pressed, the LED on the operation panel is lighted for 5 sec.

2 Fusing lamp and cooling fan operation check

(Operation/Procedure) When the START key is pressed, the fusing lamp repeats ON (500ms) and OFF (500msec) 5 times. During this period, the cooling fan rotates in the high speed mode. After completion of the operation, the cooling fan rotates in the low speed mode.

3 Copy lamp operation check

(Operation/Procedure) When the START key is pressed, the copy lamp is lighted for 5 sec.

6 1 Paper feed solenoids (CPFS1, CPFS2, MPFS) operation check

(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.

2 Resist solenoid (RRS) operation check

(Operation/Procedure) When the START key is pressed, the resist solenoid (RRS) repeats ON (500ms) and OFF (500ms) 20 times.

7 1 Warm-up time display and aging with JAM

(Operation/Procedure)

1. When the simulation is executed, warming up is started.

2. Warm-up time is counted and displayed every second on the copy quantity display.

3. After completion of warm-up, the time count is stopped and the ready lamp is lighted.

4. Press the clear key to clear the warm-up time display, set the copy quantity, and press the START key, and the machine will copy the set quantity repeatedly.

6 Intermittent aging

(Operation/Procedure)

1. When the simulation is executed, warming up is started.

2. After completion of warm-up, the ready lamp is lighted.

3. Set the copy quantity and press the START key, and the machine will copy the set quantity repeatedly.

4. After 3 sec of the interval time from completion of copying the set quantity, the machine will resume copying.

5. The above operation 4 is repeated.

10-3

Main code Sub code Contents

8 1 Developing bias check

(Operation/Procedure) When the START key is pressed, the developing bias is outputted for 30 sec.

2 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.

3 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.

6 Transfer charger check

(Operation/Procedure) When the START key is pressed, the transfer charger output is supplied for 30 sec.

10 - Toner motor operation check

(Operation/Procedure) When the START key is pressed, the toner motor output is supplied for 30 sec.

14 - Cancel of trouble other than U2

(Operation/Procedure) After canceling the trouble, the simulation is also automatically canceled.

16 - Cancel of U2 trouble

(Operation/Procedure)

1. When the START key is pressed, the EEPROM total counter check sum is rewritten and the trouble is canceled.

2. After canceling the trouble, the simulation is also automatically canceled.

22 5 Total counter value display

(Operation/Procedure) The total counter value is div i de d in to two 3-digit sections and dis pla ye d o n th e c op y q ua ntity display repeatedly.

Example of display In the case of 12345 012 → Blank → 345 → Blank → 012

0.7s 0.3s 0.7s 1.0s 0.3 s

12 Drum counter value display

(Operation/Procedure) The installed drum counter value is divided into two 3-digit sections and displayed on the copy quantity display repeatedly. * The display method is same as the total counter value display.

14 P-ROM version display

(Operation/Procedure) The P-ROM version is displayed in 3 digits on the copy quantity display.

21 Scanner counter value display

The installed scanner counter value is divided into two 3-digit sections and displayed on the copy quantity display repeatedly. * The display method is same as the total counter value display.

AL-1000/1010

10-4

AL-1000/1010

Main code Sub code Contents

24 7 Drum counter clear

(Operation/Procedure) When the START key is pressed, the drum counter value is reset to 0.

13 Scanner counter clear

(Operation/Procedure) When the START key is pressed, the scanner counter value is reset to 0.

25 1 Main motor operation check

(Operation/Procedure) When the START key is pressed, the main motor is rotated for 30 sec. To save toner consumption, the different operations are executed depending on installation of the developing unit. . When the developing unit is installed, the developing bias, the main charger, and the grid are also outputted. . When the developing unit is not installed, only the motor is rotated. * Do not turn on the door open/close switch forcibly to execute this simulation.

10 Polygon motor operation check

(Operation/Procedure) When the START key is pressed, the polygon motor is operated for 30sec.

26 1 Manual paper feed section setting

(Operation/Procedure)

1. When this simulation is executed, the currently set bypass code number is displayed.

2. Enter the code number corresponding to the bypass and press the START key, and the setting will be changed.

Code number Bypass

0 Single bypass 1 M ulti bypass

6 Destination setting

(Operation/Procedure)

1. When this simulation is executed, the currently set destination code number is displayed.

2. Enter the code number corresponding to the destination and press the START key, and the setting will be changed.

Code number Destination

0 Inch series 1 EX AB series 2 Japan AB series

7 Machine conditions check

(Operation/Procedure) When this simulation is executed, the current machine setting is displayed.

CPM Copy quantity display 10cpm 10 12cpm 12 15cpm 15

10-5

Main code Main code Contents

26 20 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

0 Rear edge void allowed 1 Rear edge void not allowed

30 CE mark application control ON/OFF setting

(Operation/Procedure)

1. When this simulation is executed, the currently set code number of CE mark application is displayed.

2. Enter the code number of CE mark application and press the START key, and the setting will be changed. Code number CE mark application setting

0 CE mark application control OFF 1 CE mark application control ON

38 Drum life over stop cancel

(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. Code number Setting

0 Stop at drum life over 1 Stop cancel at drum life over

AL-1000/1010

39 Memory capacity setting

(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. Code number Setting

0No memory 14Mbyte 26Mbyte

40 Polygon motor OFF time setting

(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. Code number Setting

00 sec 1 30 sec 2 60 sec 3 90 sec

42 Transfer ON timing control (Setting the time to transfer ON)

(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

0 Default (330 msec) 1 -40msec 2 -30msec 3 -20msec 4 -10msec 5 Default (330 msec) 6 +10msec 7 +20msec 8 +30msec 9 +40msec

10-6

AL-1000/1010

Main code Main code Main code

30 1 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

New drum cartridge sensor (PUIS) Zoom lamp

2nd CS paper sensor (PPD3) 2nd cassette lamp

Single manual feed paper detection(MFD) AE lamp

43 1 Fusing temperature setting

(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. Code number Set temperature (°C)

0 175 1 180 2 185 3 190 (*Default) 4 195 5 200

4 Multi copy fusing temperature setting

(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. Code number Set temperature (°C)

0 155 1 160 2 165 (*Default) 3 170 4 175

5 180 * To suppress temperature rise in the machine during multi copying,the fusing temperature is automatically changed from the level set with SIM 43-1 to the level set with this simulation after 20 sheets of multi copy.

46 1 Copy density adjustment

(Outline) Used to adjust the copy density in each copy mode.(The copy density can be set by changing the set value of ASIC GAMMA ADJUST register.) Setting in each copy mode is performed at exposure level 3. When the copy density (exposure) is adjusted arbitrarily, the max, and min. exposure levels are automatically calculated and set. (The change amounts (gradient, change amount) at level 1 - 5 are predetermined.) (Operation/Procedure)

1. When this simulation is executed, warming up and shading are performed and the current set value is displayed in two digits.

2. Press the copy mode select key to select each setting mode and setting display. * The copy mode setting is indicated with the following lamps as shown below.

3. Change the setting with the value up-down key and press the START key, and a copy will be made with the entered set value.

4. Press the clear key to store the set value and exit the simulation.

Copy mode Display lamp

AE mode AE mode lamp

TEXT mode TEXT mode lamp

PHOTO mode PHOTO mode lamp

TS mode (TEXT) TEXT mode lamp & PHOTO mode lamp

TS mode (AE) AE mode lamp & PHOTO mode lamp

10-7

Main code Main code Main code

46 1 Relationship between the displayed values and the GAMMA ADJUST register

Exp1 Exp2 Exp3 Exp4 Exp5 AE -24 -12 0 +12 +24 TEXT -24 -12 0 +12 +24 PHOTO -24 -12 0 +12 +24 T/S -24 -12 0 +12 +24

The value disp l ay ed after execution of thi s simulation can be s et i n 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 Then set the GAMMA ADJUST register set value to -34. Perform the same procedure for each mode and each Exp. * The above table may subject to change. * For the gradient, there is a similar table, though not specified here. The value set with SIM 46, however, is not reflected. * The AE mode Exp selection is not specified, but corresponds to the grades for AE exposure selection in the former models.

48 1 Front/rear scanning direction magnification ratio adjustment

(Outline) (1) Front/rear scanning direction magnification ratio auto correction: (Performed by changing the set value of ZOOM DATA register for asic.) The width of the reference line marked on the shading correction plate is scanned to perform the front/rear direction magnification ratio adjustment automatically. (Performed by changing the set value of ZOOM DATA register for ASIC.) (2) Front/rear scanning direction magnification ratio manual correction: Used to set the front/rear (main scanning) direction magnification ratio by key operations. (Performed by changing the set value of ZOOM DATA register for ASIC.) (3) Scanning direction magnification ratio correction: The scanning direction magnification ratio in the OC mode is set by key operations. (Performed by changing the scanning speed.) (4) SPF mode scanning direction magnification ratio correction: The scanning direction magnification ratio in the OC mode is set by key operations. (Performed by changing the scanning speed.) (Operation/Procedure)

1. When this simulation is executed, the current set value is displayed in two digits. (Center value: 50)

2. When the copy mode select key is pressed, the setting mode and the setting display are changed sequentially. * The selected adjustment mode is indicated by the lamps as follows:

3. In the front/rear scanning direction adjustment, when the START key is pressed, the mirror base unit moves to the white plate for shading and the width of the reference line is read and the correction value is calculated and displayed and the value is stored. In the case of the manual adjustment, enter the adjustment value with the 10-key and press the START key. Then the entered value is stored and a copy is made. (An increase of 1 i n the set val ue corresponds to an increase of 1&.)

4. Press the clear key to store the set value and exit the simulation. Adjustment mode Lamps ON Front/rear direction magnification ratio auto correction AE lamp Front/rear direction magnification ratio manual correction TEXT lamp Scanning direction magnification ratio correction PHOTO lamp SPF mode scanning direction magnification ratio correction AE, TEXT, PHOTO lamps

AL-1000/1010

In the front-rear direction magnification ratio correction: (1) The result of calculation of the scan correction value is +-5% or less, "- -" is displayed. (Cause) The white plate reference position error or the lens unit installing error (2) In case of a scanning error of the reference line, the JAM lamp is turned on. (Cause) CCD error or no white plate *) If the automatic correction of magnification ratio does not work properly, adjust and correct manually.

10-8

AL-1000/1010

Main code Sub code Contents

50 1 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. When this simulation is executed, the current set value is displayed in two digits. (Center value: 50)

2. When the copy mode select key is pressed, the setting mode and the setting display are changed sequentially. * The selected adjustment mode is indicated by the lamps as follows.

3. Enter the adjustment value with the 10-key and press the START key. Then the set value is stored and copy is made. (An increase of 1 in the set value corresponds to 0.1mm shift.)

4. Press the clear key to store the set value and exit the simulation.

Adjustment mode Lamps ON Print start position AE lamp

Image lead edge void amount TEXT lamp

Image scanning start position (Scanner) PHOTO lamp

Image rear edge void amount AE, TEXT, PHOTO lamps

10 Center offset adjustment

(Outline) Used to adjust the copy image position on copy paper and the center offset position in scanning an original. Performed by changing the set values of the SCAN LEFT MARGIN register and the PRINT LEFT MARGIN register of ASIC. (Operation/Procedure)

1. When this simulation is executed, the current set value is displayed.

2. In a machine with the multi paper feed unit installed, press the copy mode select key, and each setting mode and display are changed sequentially. In a machine with the single paper feed unit installed, press the copy mode select key, and each setting mode and display are changed sequentially. * The selected adjustment mode is indicated by the lamps as follows:

3. Enter the adjustment value with the 10-key and press the SORT key. Then the set value is stored and a copy is made. (An increase of 1 in the set value corresponds to 0.1mm shift.)

4. Press the clear key to store the set value and exit the simulation. * Machine with the multi manual paper feed unit installed

Adjustment mode Lamps ON

Print center offset (main cassette paper feed) AE, main cassette lamp

Print center offset (2nd cassette paper feed) AE, 2nd cassette lamp

Print center offset (Manual paper feed) AE, manual feed lamp

OC/original center offset AE, TEXT lamp

SPF/Original center offset AE, TEXT, PHOTO lamp

* Machine with the single manual paper feed unit installed

Adjustment mode Lamps ON

Print center offset (main cassette paper feed) AE, main cassette lamp

Print center offset (Manual paper feed) AE (Blink)

OC/original center offset AE, TEXT lamp

SPF/Original center offset AE, TEXT, PHOTO lamp

51 2 Resist amount adjustment

(Outline) Used to adjust the contact pressure of paper onto the copier resist roller and the SPF resist roller. (Operation/Procedure)

1. When this simulation is executed, the currently set value is displayed.

3. Enter the adjustment value with the 10-key and press the SORT key. Then the set value is stored and a copy is made.

4. Press the clear key to store the set value and exit the simulation.

10-9

Main code Sub code Contents

51 2 * 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

Adjustment mode Lamps ON

Main cassette paper feed AE, main cassette lamp

Manual paper feed AE (Blink)

SPF/Resist AE, TEXT, PHOTO lamp

61 3 Polygon motor (HSYNC output) check

(Operation/Procedure) When the START key is pressed, HSYNC is performed and the polygon motor is rotated for 30 sec. At that time, the Zoom lamp is lighted for 100msec e3very time when HSYNC is detected.

63 1 Shading check

(Outline) Used to display the detection level of the white plate for shading. (Vref of AD conversion IC is fixed.) (Operation/Procedure) When the START key is pressed, the mirror base unit moves to the white plate for shading and Vref+ voltage of AD conversion IC is set to 4.5V and Vref- voltage to 0.5V, and the copy lamp is lighted. This state is kept for 10 sec, and the level of one pixel at the center is detected every second to display on the value display section.

AL-1000/1010

64 1 Self print by engine only (1 by 2 mode)

(Outline) Used to print the set quantity in 1 by 2 mode ignoring the optical system state. (Operation/Procedure)

1. When this simulation is executed, warming up is performed and the ready lamp is lighted.

2. Enter the copy quantity with the 10-key, select the cassette with the cassette select key, and press the START

key. Paper is fed from the cassette and printing is performed. In 1 by 2 print mode, one line is printed and the following two lines are not printed.

10-10

AL-1000/1010

4. Trouble Codes

Main code Sub code Trouble content Detail of trouble

E7 03 HSYNC cannot be

detected.

E7 04

E7 05 CD black level trouble CCD drive circuit (CCD PWB, ASIC, harness) trouble E7 12 Shading trouble

E7 14

E7 15

L1 00

L3 00

L4 01 Main motor lock When the main motor encoder pulse is not detected for 100msec. L6 10

H2 00 Thermistor open detection The fusing thermistor is open. H3 00 Heat roller abnormally high

H4 00 Heat roller abnormally low

U2 01 Counter sum check error When the counter check sum value stored in the EEPROM is abnormal. U2 04 EEPROM serial

(Blinking)

- TD cartridge not installed Check if TD cartridge is installed.

CCD white level trouble

(white correction) ASIC connection trouble

Copy lamp OFF trouble

Feed is not completed within the specified time.

Return is not completed within the specified time.

Polygon motor lock

temperature

communication error

LSU (laser diode, reception element, APC circuit) trouble LSU drive circuit (ASIC) trouble CCD drive circuit (CCD PWB, ASIC harness) trouble Copy lamp lighting trouble (Copy lamp, invertor PWB)

Dirt on white plate for scanning white level Improper connection between CPU and ASIC (pattern cut, improper connection

of lead pin) Copy lamp or copy lamp drive circuit (invertor PWB) trouble Copy lamp disconnection When the mirror base is r etu rn ed for the specified time (6 sec) in mirror initializing after turning on the power, the mirror home position sensor (MHPS) does not turn OFF. Or when the mirror base is fed for the specified time (about 6 sec) after start of copy return, the mirror home position sensor (MHPS) does not turn OFF.

When the mirror base is returned for the specified time (6 sec) in mirror initializing after turning on the power, the mirror home position sensor (MHPS) does not turn ON.Or when the mirror base is returned for the specified time (about 6 sec) after start of copy return, the mirror home position sensor (MHPS) does not turn ON.

The lock signal (specified rpm signal) does not return within a certain time (about 20sec) from starting the polygon motor rotation

The fusing temperature rises above 240°C. The fusing temperature does not reach 185°C within 27 sec of turning on the

power, or the fusing temperature keeps at 140°C.

When a communication trouble occurs with the EEPROM.

10-11

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

●

Auto clear.

Pre-heat.

Auto shut off passing time.

Stream feeding. Only models with SPF. Set Auto shut off setting

∗Note: The power consumption values in pre-heat and auto shut off may be varied depending on the use conditions.

Change the setting.

Example: Changing the time to operate the auto shut off func-

tion (Change from 60 sec to 90 sec)

1. Press the right and the left exposure adjustment keys simultaneously to start setting.

● Keep pressing the keys for five sec.

● Display lamps ( , , blink simultaneously and “-

-” is displayed on the copy quantity display.

2. Select the function code with the 10-digit key (copy quantity set key).

● The number of the selected function blinks on the digit of 10

on the copy quantity display.

● For auto clear, select “1.”

● For setting, refer to the following function codes.

When a certain time is passed after completion of copying, this function returns to the initial state automatically. The time to reach the initial state can be set in the range of 30 sec to 120 sec by the unit of 30 sec. This function can be disabled.

●

When the copier is left unused with the power ON, the power consumption is automatically reduced to about 40Wh/H (∗ Note). The time to start this function can be set in the range of 30 sec to 90 sec by the unit of 30 sec. This function cannot be disabled.

●

When this function is operated, the pre-heat lamp on the operation panel lights up. To return to the initial state, press any key on the operation panel. (When the COPY button is pressed, a copy is made after returning to the initial state.)

●

When the copier is left unused with the power ON, the power consumption is automatically reduced to about 18Wh/H (∗ Note). The time to start this function can be set in the range of 2 min to 120 min.

●

When this function is operated, all the lamps except for the pre-heat lamp on the operation panel turn off. To return to the initial state, press the COPY button.

●

Used to set or cancel this function. Set

Function name Function code Auto clear 1 Pre-heat 2 Auto shut off passing time 3 Stream feeding 4 Auto shut off setting 5

[Cancel] If a wrong code is entered, press the clear key and

enter the correct function code.

✽ SPF only

3. Press the COPY button.

● The number blinking on the digit of 10 of the coyp quantity display is lighted.

● The number of the current set code blinks on the digit of 1.

4. Select the setting code with 1-digit key (copy

quantity set key).

● To set to 90 sec, select “3.”

● For setting, refer to the following set codes.

60 sec

90 sec

5 min

✽

Function name

Auto clear

∗ : Factory setting

● The number of the selected set code blinks on the digit of 1 of the copy quantity display.

[Cancel] When a wrong number of the function code is set,

Set code

0 (Cancel) 1 (30 sec) 1 (60 sec) ∗1 (5 min) ∗1 (Setting) ∗1 (Setting)

∗2 (60 sec) 2 (90 sec) 2 (15 min)

3 (90 sec) 3 (30 min)

4 (120 sec) 4 (60 min)

press the clear key and perform the procedure again from 2.

Function name

Pre-heat

Set code

0 (30 sec)

Function name

Auto shut off

5. Press the COPY button.

● The number blinking on the digit of 1 of the copy quantity display is lighted up. This means the setting is completed.

Set code 0 (2 min)

5 (120 min)

[Note] To set another function, press the clear key after com-

Function name

Stream feeding

pletion of this operation and perform the procedure from 2.

Set code

0 (Cancel)

Function name

Auto shut off setting

6. Press either one of exposure adjustment keys ( or ) to complete the setting.

● Display lamps ( , , ) go off and the copy quan-

tity display returns to the normal state.

11-1

Set code

0 (Cancel)

AL-1000/1010

[12] ELECTRICAL SECTION

1. Block diagram

A. Overall block diagram

Printed Visual Data

MIRROR MOTOR

CRU Reset Switch

Other Loads

VFM

CPFS1

LASER

MAIN MOTOR

RRS

MPFS

COPY LAMP

OPE PANEL

CCD

LSU

SERIAL

SRAM

Reference

AND

ASIC

EPROM SRAM EEPROM

CPU

MCU PWB

JITTER SYNC IC

RESET IC

Toner Motor

AND

UART

Other Inputs

MHPS

POD

MMLD

INTERLOCK SWITCH

24V 5V GND

Power Unit

RTH

PPD1 PPD2

3.3V12V FW

TCS DVSEL

CED1MHPS

BIAS TCPRHLOUT

MC GRIDL

High Voltage Control Unit

AC PWB

AC100/110/120/127/230V Source

12-1

B. Main PWB block diagram (Load drive block diagram)

MAIN CHARGER

GRID CONTROL

TRANSFER CHARGER

DEVELOPING BIAS

CCD PWB

CCDLO

CCDHI

etc...

CCDD0 `7

DV SENSOR

DVSEL

etc...

CN121

/GRIDL

/BIAS

CN113

IC125

IC112

IC106

IC107

/MC

/TC

CONTROL UNIT

HIGH VOLTAGE

IC104

POWER

SOURCE

ELECTRIC

/PR

CN109

IC102

RELAY

IC103

THERMISTOR

HEATER LAMP

HLOUT

IC114

INTERLOCK

24V(DSW

5V(DSWS)

CN107

IC112

RTH-IN

INTERLOCK

IC115

IC119

IC107

IC104

(Inside of FUSER)

PAPER PATH DETECTOR 2

PPD2

CN112

CN104

/CL

IC103

CN118

CN119

/VFMCNT

VFMOUT

IC112

AL-1000/1010

PPD1

(Near PS ROLLER)

PAPER PATH DETECTOR 1

COPY LAMP

FANMOTOR

VENCH RATION

(OPTIONAL)

DRAM PWB

GDI PWB

POLIGON

LSU UNIT

BUSY

/ACK

(OPTIONAL)

DATA

/SLCTIN

INIT

DATA

HSYNC

MOTOR

PMRDY

/SLCTIN

/FAULT

/STB

/AUTOFD

/LDEN

S/H

/VIDEO

/PMD

PMCLK-A

/REV

CN123

CN110

CN115

IC116

IC107

CN106

IC114

IC107

IC103

CN102

IC108

ASIC(HG73C025FD)

IC111

IC103

IC112

CN105

CPU(H8S/2350)

IC110

IC112

IC107

CN111

IC103

CN103

IC114

IC107

CN117

IC101

IC107

IC118

IC102

IC114

IC112

IC113

CN101

CN113

CN120

CN122

CN114

CN116

TMb-O

TMa-O

MRMT0 `3

MHPS

/MM

MMLD

DRST

OP-DATA

OP-LATCH

OP-CLK

KIN2

KIN1

PSW

TCS

MOTOR

TONER

SENSER

CONTROL

TONER

MOTOR

MIRROR

POSITION

HOME

MIRROR

MOTOR

MAIN

LOCK

MOTOR

MAIN

KEY

SENSER

DETECTO

SENSER

NEW PROCESS UNIT

/CPFS1

/CED1

SOLENOID

PAPER FEED

DETECTOR

TRAY EMPTY

ARZ300 SERIES MAIN PWB A BLOCK DIAGRAM

CPWBX0010QS**

CASSETTE1

PAPER

/CED2

CASSETTE2

PAPER

/CPFS2

SOLENOID

PAPER FEED

DETECTOR

TRAY EMPTY

(OPTIONAL)

/MPFS

MFD

PPD3

SOLENOID

PAPER FEED

DETECTOR

PAPER

(Near CASSETTE2)

PAPER FEED

MANUAL

PAPER PATH DETECTOR 3

12-2

/RRS

POD

SOLENOID

RESIST ROLLER

DETECTOR

PAPER EXIT

OPERATION PWB A (for Copier/GDI)

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

1 /CS1 Output Chip Select for SRAM 2 /CS0 Output Chip Select for EPROM 3 D-GND 4 D-GND 55V 6 A0 Output Address Bus (NC-pull up) 7 A1 Output Address Bus 8 A2 Output Address Bus

9 A3 Output Address Bus 10 Output D-GND 11 A4 Output Address Bus 12 A5 Output Address Bus 13 A6 Output Address Bus 14 A7 Output Address Bus 15 A8 Output Address Bus 16 A9 Output Address Bus 17 A10 Output Address Bus 18 A11 Output Address Bus 19 Output D-GND 20 A12 Output Address Bus 21 A13 Output Address Bus 22 A14 Output Address Bus 23 A15 Output Address Bus 24 A16 Output Address Bus 25 A17 Output Address Bus (for 2Mbit EPROM) - (NC) 26 A18 Output Address Bus (NC-pull up) 27 A19 Output Address Bus (NC-pull up) 28 D-GND 29 A20 Output Address Bus (NC-pull up) 30 NC-pull up 31 NC-pull up 32 (Interruption input) NC-pull up 33 (MHPS) Interruption level input Mirror Home Position Sensor 34 /CPUSYNC Interruption level input Horizontal Synchronous (from G/A) 35 D-GND 36 D-GND 37 ZC Interruption level input Zero-cross signal 38 /ASICINT Interruption level input Intterupt from G/A 39 5V 40 D0 Data input/output Data Bus 41 D1 Data input/output Data Bus 42 D2 Data input/output Data Bus 43 D3 Data input/output Data Bus 44 D-GND

12-3

PIN No Signal code Input/output Operating

45 D4 Data input/output Data Bus 46 D5 Data input/output Data Bus 47 D6 Data input/output Data Bus 48 D7 Data input/output Data Bus 49 D8 Data input/output Data Bus 50 D9 Data input/output Data Bus 51 D10 Data input/output Data Bus 52 D11 Data input/output Data Bus 53 D-GND 54 D12 Data input/output Data Bus 55 D13 Data input/output Data Bus 56 D14 Data input/output Data Bus 57 D15 Data input/output Data Bus 58 5V 59 (OP-DATA) Output Data Signal for Operation Panel 60 NC-pull up 61 NC-pull up 62 NC-pull up 63 (OP-CLK) Output Clock for Operation Panel 64 /PWOFF Output Power Off 65 D-GND 66 NC-pull up 67 D-GND 68 D-GND 69 PSW Input Print switch input 70 KIN1 Input Key input 1 71 KIN2 Input Key input 2 72 TMCLK Timer output Clock for Toner Motor 73 /TMEN Output On-Off Control for Toner Motor 74 NC-pull up 75 PMCLK Timer output Clock for Polygon Motor 76 /PRSTART Output Printing Start Signal 77 /SCANSP Output Scaning Stop Signal 78 /SCANST Output Scaning Start Signal 79 HL OutputüiTimer outputüj On-Off Control for Heatrer Lamp 80 WDTOVF- Output Watchdog Timer 81 RES- Input Reset 82 Input pull up 83 Input pull up 84 5V 85 XTAL Clock 86 EXTAL Clock 87 D-GND 88 CPUCLK Output System Clock for G/A 89 5V 90 /AS Output pull up 91 /RD Output Read Signal 92 /HWR Output Write Signal (High Address) 93 /LWR Output Write Signal (Low Address)

AL-1000/1010

12-4

AL-1000/1010

PIN No Signal code Input/output Operating

94 SELIN3 Output Input select 3 95 SELIN2 Output Input select 2 96 SELIN1 Output Input select 1 97 PR Output Power relay control PR 98 RRS Output Resist roller solenoid RPC 99 D-GND

100 D-GND 101 SCLK Output Clock Line for EEPROM 102 SDA Output Data Line for EEPROM 103 A5V 104 Analog Reference Voltage-A5V 105 RTH Analog input Fusing Thirmister 106 107 SIN1 Input Sensor input 1 108 SIN2 Input Sensor input 2 109 SIN3 Input (Not used) 110 SIN4 Input (Not used) 111 DAH Analog output Reference Voltage (High) for CCD 112 DAL Analog output Reference Voltage (Low) for CCD 113 AN-GND 114 D-GND 115 NC-pull up 116 NC-pull up 117 NC-pull up 118 NC-pull up 119 MRMT3 Motor output Mirror Motor Excitement 120 MRMT2 Motor output Mirror Motor Excitement 121 MRMT1 Motor output Mirror Motor Excitement 122 MRMT0 Motor output Mirror Motor Excitement 123 Input CPU MODE SET <MODE 4> - GND 124 Input CPU MODE SET <MODE 4> - GND 125 Input CPU MODE SET <MODE 4> - Vcc 126 NC-pull up 127 DRST Input Drum reset detection 128 /CS2 Output Chip Select for ASIC

12-5

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. and zooming. The print control section outputs the image-processed data during copying to the LSU (Laser unit) in synchronization with writing timing of the LSU. The I/F section controls communication of interface (IEEE1284) with the host PC and controls DRAM of send/receive data buffer with the host PC. (Only for models with the printer function) The ASIC is controlled by the CPU which writes the operation mode and the set values necessary for each operation mode to the ASIC control register.

Scan start

CCD PWB

Shading

ASIC

Image process section

CCD drive

Resolution conversion, Zooming, lmage process circuit

SRAM control

SRAM 32KB x 2

Print control section

Print data process circuit

DRAM control

I/F section

DRAM 6MB or 4MB

PRINT control

IEEE1284 control

ASIC control resistor

LSU

HSYNC VSYNC

TO PCI/F PWB

(Only for models withthe printer function)

To CPU bus

12-6

AL-1000/1010

2. ASIC input/output PIN No. Signal name IN/OUT Connected to Description

1 /SCANSP IN CPU (I/O) Scanner process interrupt signal 2 /PRSTART IN CPU Print start trigger signal 3 TMON IN CPU Toner motor ON/OFF 4 TMCLK IN CPU Toner motor reference clock 5 3.3v Power 6 CPUAD7 IN CPU CPU address bus 7 CPUAD6 IN CPU CPU address bus 8 GND Power

9 CPUAD5 IN CPU CPU address bus 10 CPUAD4 IN CPU CPU address bus 11 CPUAD3 IN CPU CPU address bus 12 CPUAD2 IN CPU CPU address bus 13 CPUAD1 IN CPU CPU address bus 14 /CPUSYNC OUT CPU Horizontal synchronization signal 15 /INTR OUT CPU Interruption request signal 16 /CPUCS IN CPU CPU chip select signal 17 /RESET IN RESET IC Reset signal 18 5V Power 19 GND Power 20 3.3v Power 21 GND Power 22 MDATA15 IN/OUT DRAM Data bus of DRAM (page memory) 23 MDATA14 IN/OUT DRAM Data bus of DRAM (page memory) 24 MDATA13 IN/OUT DRAM Data bus of DRAM (page memory) 25 MDATA12 IN/OUT DRAM Data bus of DRAM (page memory) 26 MDATA11 IN/OUT DRAM Data bus of DRAM (page memory) 27 MDATA10 IN/OUT DRAM Data bus of DRAM (page memory) 28 MDATA9 IN/OUT DRAM Data bus of DRAM (page memory) 29 MDATA8 IN/OUT DRAM Data bus of DRAM (page memory) 30 MDATA7 IN/OUT DRAM Data bus of DRAM (page memory) 31 3.3v Power 32 MDATA6 IN/OUT DRAM Data bus of DRAM (page memory) 33 MDATA5 IN/OUT DRAM Data bus of DRAM (page memory) 34 GND Power 35 MDATA4 IN/OUT DRAM Data bus of DRAM (page memory) 36 MDATA3 IN/OUT DRAM Data bus of DRAM (page memory) 37 MDATA2 IN/OUT DRAM Data bus of DRAM (page memory) 38 MDATA1 IN/OUT DRAM Data bus of DRAM (page memory) 39 MDATA0 IN/OUT DRAM Data bus of DRAM (page memory) 40 /RAS0 OUT DRAM RAS signal 0 of DRAM (page memory) 41 /RAS1 OUT DRAM RAS signal 1 of DRAM (page memory) 42 /RAS2 OUT DRAM RAS signal 2 of DRAM (page memory) 43 /RAS64 OUT DRAM (Not used) 44 3.3V Power 45 /RAS16 OUT DRAM (Not used) 46 MAD0 OUT DRAM Address bus of DRAM (page memory) 47 GND Power 48 MAD1 OUT DRAM Address bus of DRAM (page memory)

12-7

PIN No. Signal name IN/OUT Connected to Description

49 MAD2 OUT DRAM Address bus of DRAM (page memory) 50 MAD3 OUT DRAM Address bus of DRAM (page memory) 51 MAD4 OUT DRAM Address bus of DRAM (page memory) 52 MAD5 OUT DRAM Address bus of DRAM (page memory) 53 MAD6 OUT DRAM Address bus of DRAM (page memory) 54 MAD7 OUT DRAM Address bus of DRAM (page memory) 55 MAD8 OUT DRAM Address bus of DRAM (page memory) 56 MAD9 OUT DRAM Address bus of DRAM (page memory) 57 3.3V Power 58 MAD10 OUT DRAM Address bus of DRAM (page memory) 59 MAD11 OUT DRAM Address bus of DRAM (page memory) 60 GND Power 61 /CAS0 OUT DRAM CAS signal of DRAM (page memory) 62 /CAS1 OUT DRAM CAS signal of DRAM (page memory) 63 /OE OUT DRAM Read enable signal of DRAM (page memory) 64 /WE OUT DRAM Write enable signal of DRAM (page memory) 65 OUTD0 OUT Additional board (Not used) 66 OUTD1 OUT Additional board (Not used) 67 OUTD2 OUT Additional board (Not used) 68 OUTD3 OUT Additional board (Not used) 69 3.3V Power 70 OUTD4 OUT Additional board (Not used) 71 OUTD5 OUT Additional board (Not used) 72 GND Power 73 OUTD6 OUT Additional board (Not used) 74 OUTD7 OUT Additional board (Not used) 75 OUTD8 OUT Additional board (Not used) 76 OUTD9 OUT Additional board (Not used) 77 OUTD11 OUT Additional board (Not used) 78 OUTD10 OUT Additional board (Not used) 79 OUTD12 OUT Additional board (Not used) 80 OUTD13 OUT Additional board (Not used) 81 OUTD14 OUT Additional board (Not used) 82 OUTD15 OUT Additional board (Not used) 83 /HSYNC OUT FAX board (Not used) 84 /PCLPRD IN PCL board (Not used) 85 /PCLREQ OUT PCL board (Not used) 86 /PCLACK IN PCL board (Not used) 87 /PCLCS IN PCL board (Not used) 88 3.3V Power 89 GND Power 90 5V Power 91 GND Power 92 /FAXPRD IN FAX board (Not used) 93 /FAXREQ OUT FAX board (Not used) 94 /FAXACK IN FAX board (Not used) 95 3.3V Power 96 /FAXCS IN FAX board (Not used)

AL-1000/1010

12-8

AL-1000/1010

PIN No. Signal name IN/OUT Connected to Description

97 /ESPRD IN 98 GND Power 99 /ESREQ OUT

100 /ESACK IN

101 /ESCS IN 102 PARAD0 IN/OUT 1284CN board (Not used)

103 PARAD1 IN/OUT 1284CN board (Not used) 104 PARAD2 IN/OUT 1284CN board (Not used) 105 PARAD3 IN/OUT 1284CN board (Not used) 106 PARAD4 IN/OUT 1284CN board (Not used) 107 PARAD5 IN/OUT 1284CN board (Not used) 108 5V Power 109 PARAD6 IN/OUT 1284CN board (Not used) 110 PARAD7 IN/OUT 1284CN board (Not used) 111 GND Power 112 /REV OUT 1284CN board (Not used) 113 INIT IN 1284CN board (Not used) 114 /SLCTIN IN 1284CN board (Not used) 115 /AUTOFD IN 1284CN board (Not used) 116 /STB IN 1284CN board (Not used) 117 /ACK OUT 1284CN board (Not used) 118 BUSY OUT 1284CN board (Not used) 119 PE OUT 1284CN board (Not used) 120 /FAULT OUT 1284CN board (Not used) 121 5V Power 122 SLCT OUT 1284CN board (Not used) 123 /TESTPIN0 IN TEST PIN High: Normal Low: Test 124 GND Power 125 PFCLK IN Transmitter Write clock 126 /TESTPIN1 IN TEST PIN High: Normal Low: Test

127 /SYNCEN OUT

128 SD10 IN/OUT

129 SD11 IN/OUT

130 SD12 IN/OUT

131 SD13 IN/OUT

132 SD14 IN/OUT 133 5V Power 134 SD15 IN/OUT

135 SD16 IN/OUT

Electronic sort board

JITTER ADJUSTMENT IC

SRAM (separation)

(Not used)

Jitter adjustment IC trigger signal

Data line to SRAM before are separation

12-9

PIN No. Signal name IN/OUT Connected to Description

136 GND Power 137 SD17 IN/OUT

138 SOE1 OUT

139 SWE1 OUT

140 SCS1 OUT

141 SOE0 OUT

142 SWE0 OUT

143 SCS0 OUT

144 SD00 IN/OUT

145 SD01 IN/OUT 146 5V Power 147 SD02 IN/OUT

148 SD03 IN/OUT 149 GND Power 150 SD04 IN/OUT

151 SD05 IN/OUT

152 SD06 IN/OUT

153 SD07 IN/OUT

154 SAD0 OUT

155 SAD1 OUT

156 SAD2 OUT

157 SAD3 OUT

158 SAD4 OUT

159 SAD5 OUT

160 SAD6 OUT

161 SAD7 OUT 162 GND Power 163 SAD8 OUT

164 SAD9 OUT

SRAM (separation)

Data line to SRAM before are separation

Read enable line to SRAM before area separation

Write enable line to SRAM before area separation

Chip select line to SRAM before area separation

Read enable line to SRAM before area separation

Write enable line to SRAM before area separation

Chip select line to SRAM before area separation

Data line to SRAM before are separation

Address line to SRAM before area separation

AL-1000/1010

12-10

AL-1000/1010

PIN No. Signal name IN/OUT Connected to Description

165 SAD10 OUT

166 SAD11 OUT

167 SAD12 OUT

168 SAD13 OUT 169 /f1 OUT CCD PWB CCD drive signal transfer clock (First phase)

170 /f2 OUT CCD PWB CCD drive signal transfer clock (Second phase) 171 /SH OUT CCD PWB CCD drive signal shift pulse 172 5V Power 173 RS OUT CCD PWB CCD drive signal reset pulse 174 SP OUT CCD PWB CCD drive signal sampling hold pulse 175 GND Power 176 CP OUT CCD PWB A/D conversion IC latch clock 177 BCLK OUT CCD PWB CCD shield output latch signal

178 IDIN0 IN

179 IDIN1 IN

180 IDIN2 IN

181 IDIN3 IN

182 IDIN4 IN

183 IDIN5 IN

184 IDIN6 IN 185 5V Power 186 IDIN7 IN 187 /SDCLK OUT CHECK Effective image area signal

188 GND Power 189 SFCLK IN Transmitter CCD drive clock (48MHz), Also used as an internal clock.

190 TEST port 0 IN 191 /SYNC IN LSU Horizontal synchronization signal (HSYNC) from LSU

192 /LD OUT LSU Laser drive signal 193 /LEND OUT LSU Laser APC signal 194 PORTOUT28 OUT (Not used) 195 PORTOUT27 OUT (Not used) 196 PORTOUT26 OUT (Not used) 197 3.3V Power 198 PORTOUT25 OUT (Not used) 199 PORTOUT24 OUT (Not used) 200 GND Power 201 PORTOUT23 OUT (Not used) 202 PORTOUT22 OUT (Not used) 203 PORTOUT21 OUT (Not used)

SRAM (separation)

CCD PWB (AD conversion)

AUTO SCAN TEST

Address line to SRAM before area separation

Image scan data (after 8bit A/D conversion)

High: Normal Low: Test

12-11

AL-1000/1010

PIN No. Signal name IN/OUT Connected to Description

204 PORTOUT20 OUT (Not used) 205 OP-LATCH OUT Tr array IC Latch signal for operation circuit. Data latch at LOW. 206 MRPS2 OUT Tr array IC Mirror speed control signal. Mirror speed 2 at LOW. 207 MRPS1 OUT Tr array IC Mirror speed control signal. Mirror speed 1 at LOW. 208 PORTOUT16 OUT (Not used) 209 PORTOUT15 OUT (Not used) 210 3.3V Power 211 TC OUT Tr array IC Transfer charger control signal. ON at HIGH. 212 GRIDL OUT Tr array IC Main charger grid control signal. ON at HIGH. 213 GND Power 214 MC OUT Tr array IC Main charger control signal. ON at HIGH. 215 BIASL OUT Tr array IC DV bias voltage control signal. ON at HIGH. 216 BIASH OUT Tr array IC DV bias voltage control signal. ON at HIGH. 217 BIAS OUT Tr array IC DV bias output control signal. ON at HIGH. 218 CL OUT Tr array IC Copy lamp control signal. ON at HIGH.

219 VFMCNT OUT Tr array IC 220 VFM OUT Tr array IC Ventilation fan control signal. Fan ON at HIGH.

221 LDEN OUT Tr array IC Laser circuit control signal. Laser circuit ON at HIGH. 222 PMD OUT Tr array IC Polygon motor control signal. Polygon motor ON at HIGH. 223 5V Power 224 MM OUT Tr array IC Main motor control signal. Main motor ON at HIGH.

225 MPFS OUT Tr array IC 226 GND Power 227 CPFS2 OUT Tr array IC

228 CPFS1 OUT Tr array IC 229 TM OUT Tr array IC Toner motor drive output (+)

230 TM_ OUT Tr array IC Toner motor drive output (–) 231 CPUD15 IN/OUT CPU CPU data bus 232 CPUD14 IN/OUT CPU CPU data bus 233 CPUD13 IN/OUT CPU CPU data bus 234 CPUD12 IN/OUT CPU CPU data bus 235 CPUD11 IN/OUT CPU CPU data bus 236 5V Power 237 CPUD10 IN/OUT CPU CPU data bus 238 CPUD9 IN/OUT CPU CPU data bus 239 GND Power 240 CPUD8 IN/OUT CPU CPU data bus 241 CPUD7 IN/OUT CPU CPU data bus 242 CPUD6 IN/OUT CPU CPU data bus 243 CPUD5 IN/OUT CPU CPU data bus 244 CPUD4 IN/OUT CPU CPU data bus 245 CPUD3 IN/OUT CPU CPU data bus 246 CPUD2 IN/OUT CPU CPU data bus 247 CPUD1 IN/OUT CPU CPU data bus 248 CPUD0 IN/OUT CPU CPU data bus 249 3.3V Power

Ventilation fan rotating speed control signal. Low speed at HIGH, high speed at LOW.

Manual paper feed solenoid control signal. Multi paper feed ON at HIGH.

Second cassette paper feed solenoid control signal. Second cassette paper feed at HIGH.

Cassette paper feed solenoid control signal. One-stage cassette paper feed at HIGH.

12-12

AL-1000/1010

PIN No. Signal name IN/OUT Connected to Description

250 /CPUWR IN CPU CPU write signal 251 /CPURD IN CPU CPU read signal 252 GND Power 253 CPUCLK IN CPU CPU system clock 254 GND Power

255

TEST PORT1

AUTO SCAN TEST

High: Normal Low: Test

256 /SCANST IN CPU (I/O) Scanner process start signal

(3) Reset circuit

This circuit detects ON/OFF of power to control start/stop of each circuit. The 5V voltage of the main PWB is detected by the reset IC to generate the reset signal. When the power voltage reaches the specified level, the circuit operations are started. Before the power voltage falls below the specified level, the circuit operations are stopped to prevent against malfunctions.

R266

R265

C190

C154

IC108D

C155

C156

To ASIC

IC105

Rest IC

12-13

(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 inputted 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.

AL-1000/1010

Thermistor

Heat roller

IC112

Driver

IC114

ANo

Q104

DTA143XKA

HL-HL

R112 120J1/4W

HLOUT(5-A4)

CPU IC110

Driver IC103

PR-

Thermostat

THOPEN

Selector

RY1

+24V

PR-

Heater lamp

HLOUT

TRC1

PC2

12-14

AL-1000/1010

The lower the heat roller surface temperature is, the greater the thermistor resistance is, and vise versa. Therefore, the lower the heat roller surface temperature is, the higher the thermistor terminal voltage is, and vise versa. The thermistor terminal voltage is inputted to the CPU analog port. The CPU controls ON/OFF of the heater lamp by this input voltage level.

[High temperature protect circuit in case of CPU hung up]

For IC119 3pin (reference voltage), +5V is divided by the resistor. The thermistor terminal voltage is inputted to IC119 2pin. When, therefore, the voltage at 2pin becomes lower than the voltage at 3pin (when the heat roller temperature is about 220 C - 230˚C), IC119 1pin becomes HIGH, and the HL signal is lowered to the GND level through IC114, stopping generation of the heater lamp ON signal. (IC119 1pin is normal LOW.)

[When the heat roller surface temperature is lower than the set level]

a. Since the thermistor terminal voltage is higher than the set

level, the HL signal from the CPU becomes HIGH.

b. The HL signal is turned to be the HLOUT signal through

IC114 protect circuit, and inputted to the photo triac coupler (PC2).

c. When the internal triac turns on, a pulse is applied to the

gate of the external triac. Consequently a current flow from the power source through the heater lamp to the triac, lighting the heater lamp.

(6) Toner supply motor drive circuit

The IC101 is the motor control IC, which generates the pseudo AC waveform with the pulse signals (TM, TM-) outputted from ASIC, driving the toner supply motor.

24V

ASIC

TM-

R208 47KJ

Internal circuit

+5V +24V

REG

Protection circuit (Heat insulation)

+5V

R201 47KJ

IC101

2 9

IN1

IN2

GND

TA7291S

7 3

TMa TMb

+ 10µF35V

TMa

TMb

C201

+24V

[When the heat roller surface temperature is higher than the set level]

a. Since the thermistor terminal voltage becomes lower than

the set value, the HL signal from the CPU becomes LOW.

b. The HL turns LOW, the PC2 turns OFF, the external triac

turns OFF, and the heater lamp turns OFF.

[In case of the thermistor open]

The voltage at IC119 6pin over the voltage at 5pin to drive the output THOPEN at 7pin to LOW. This is passed through the selector to the CPU and the trouble code “H2” is displayed.

(5) Driver circuit (Solenoid)

(1) Outline Since the control signal of each load outputted from the CPU cannot drive the load directly, it is passed through the driver IC to the load.

(2) Operation The driver circuit forms a Darlington circuit with transistors. Therefore a large drive current is obtained from a small current (CPU output current). When the driver input voltage is HIGH (+5V), the transistor turns ON to flow a current in the arrow direction, operating the load. When the driver is ON, the driver output terminal voltage is 0V.

TMa TMb

GND

4pin is NC pin.

(7) Main motor drive circuit

The main motor is driven by the MM signal from ASIC. While the main motor is rotating, the MM signal is driven to HIGH and passed through IC114 to the control circuit in the main motor to rotate the main motor. The MMLD signal is kept HIGH until the main motor speed reaches the specified rpm, and passed through the selector to the CPU.

IC111

IC110

ASIC

CPU

SIN2

1 2 3 4 5 6 7 8

IC112

Selector

IC114

IN1 IN2 IN3 IN4 IN5 IN6 IN7 GND

TD62503F

MMLD

OUT1 OUT2 OUT3 OUT4 OUT5 OUT6 OUT7

COM

Main motor control circuit (in main motor)

16 15 14 13 12 11 10

MM-

CPU

OUT PUT

+24V

LOAD

12-15

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.

ASIC

C357

47µF

470PF

100J

C273

C257

R346

25V

R340

47KJ

R339

47KJ

R345

750J

CPU

@@@@@@@@@@@@@@@

R296

620J

R297

IC114

470PF

1J2W

SLA7027MU

R165

R114

R338

R344

2.4KJ

C276

2200PF

IN /A

IN/B 17IN B

IN A

GA15GB

1J2W

2.4KJ

C254

2200p

REFB10RSB

OUT A

OUT B18OUT B

IC118

TDA

RSA3REFA

TDB

OUT A

VSA12VSB

47µ35V

C321

ICP-N38(ROHM)

CP101

24V

Mirror motor

12-16

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. In the high voltage circuit section, the 24V output of the main section is switch-converted by the DC/DC convertor and rectified and smoothed to form the high voltage output. The FW signal section fullwave-rectifies the AC power to supply signal output at the timing of 0V.

ACin

Main section

High voltage section

Noise filter

Rectifying/ smoothing

Invertor circuit

Transformer T1

PC1

Rectifying/ smoothing

Control

Invertor

Series regulator

voltage

High transformer T101

Series regulator

3.3V

12V

24V

MC IN

DV BIAS BIAS

FW control section

Heater lamp drive circuit section

Heater lamp output

Full-wave rectifying

PC3

PC2

RY1

Invertor

TC High voltage transformer T102

Series regulator

Dividing circuit

GRID GRID L

BC TC IN

/PR

12-17

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. The normal mode noises are noises which are generated in the AC line or the output line and are attenuated by C4B and C3. The common mode noises are noise voltages generated between the AC line and GND, and are attenuated by L1 and L2. The noise composition is bypassed to GND through C4 and C5.

b. Rectifying/smoothing circuit

The AC voltage of 50(60)Hz is full-wave rectified by the rectifying diode DB1 and smoothed by the smoothing capacitor C6. TH1 is the power thermistor which limits a rush current flowing to C6.

AL-1000/1010

C. Invertor circuit

The DC voltage from the rectifying/smoothing circuit is supplied to the secondary side of transformer T1 by switching operation of FET Q1. For switching, the RCC (Ringing Choke Convertor) system is employed. FET Q1 is turned on by the starting resistors R20 and R1 to generate a voltage between terminals 4 and 6 of transformer T1 and between terminals 2 and 3 simultaneously. Then a voltage is applied to the gate of FET Q1 to oscillate high frequency. The actual line in the circuit diagram shows the current to turn ON FET Q1, and the dotted line shows the current loop through which the energy accumulated in the transformer is discharged when FET Q1 is turned OFF.

Voltage across Q1 drain and source (VDS)

Q1 drain current (ID)

d. Rectifying/smoothing circuit on the secondary side

The high frequency pulse generated by the invertor circuit is dropped by transformer T1, rectified by diodes D51, D52, and D53, and smoothed by capacitors C51, C52, C53, and C54.

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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. LOW level output of FW signal is provided.

e. Control circuit

The secondary side outputs (24V series, 5V series) are detected by the output voltage detecting circuit, and the detected signal is fed-back through photo coupler PC1 to the control transistor Q2 to change the ON period of FET Q1 in the primary side invertor circuit, stabilizing the output voltage.

f. Series regulator circuit

This circuit stabilizes the output and protect against an overcurrent by the series regulator. The 12V is composed of IC51, the 5V is composed of IC52, the 3.3V is composed of IC53.

(3) Heater lamp drive circuit

(4) High voltage section

a. Invertor circuit

The 24V output of the main section is inverted by the RCC system and the high frequency power is supplied to the secondary side of high voltage transformer T101 and T102. The diode and the capacitor for rectifying and smoothing are built in the secondary side of high voltage transformer T101 and T102 to provide DC outputs of high voltage. MC is turned ON/OFF by MC IN terminal, and TC is turned ON/OFF by TC IN terminal.

b. Series regulator

The GRID output of DV BIAS is applied from the MC output and dropped by the series regulator. DV BIAS is turned ON/OFF by BIAS terminal, and the GRID voltage is switched by GRID L terminal.

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c. Dividing circuit

BD OUT takes out a voltage from T102 and divides it with the resistor and outputs it.

(10) Cl invertor PWB (circuit)

CL- (CNT)

AL-1000/1010

CL (Xenon lamp)

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 transforme r.

Invertor circuit and transformer

Output 1.5kV (effective voltage)

(11) CCD PWB operational description

The CCD PWB is provided with the CCD (Charge-Coupled Device), the differential amplifier which amplifies CCD signals, and the AD convertor which converts the amplified signals into digital signals.

The DC power and the pulse supply pins necessary for operating the CCD image sensor are the power source (CD pin), GND (SS pin), shift pulse (SH pin), transfer pulse (φ1 pin), (φ2 pin), reset pulse (/RS pin), clamp pulse (/CP pin), and sampling (/SP pin). Photo data are stored in the light receiving element at the center of the CCD by the SH signal. Even number pixel data are sent to one of the two shift registers which are positioned at both ends of the light receiving element, and odd number pixel data are sent to the other shift register. The time interval between inputting two SH signals is called the photo accumulation time. The signals are transfered to the register, then to the shift register sequentially by transfer pulses ???1 and ???2 and to the floating capacitor section where electric signals are voltage-converted. Electric charges from the even number pixel shift register and the odd number pixel shift register are flowed to the floating capacitor section alternatively.

12V

CCD analog shift register 1

Photo diode

Output

CCD analog shift register 2

The /RS signal is the reset signal of the CCD output signal. The CCD output is expressed as electric charges equivalently accumulated in the capacitor. Therefore, to take the CCD output data one pixel by one pixel, one output data must be cleared after it is outputted. The /RS signal is used for that operation.

Photo energy

Photo diode

The /SP pulse signal is the peak hold signal of the signal voltage. The output signal from the CCD is amplified by about 4.7 times greater in the differential amplifier circuit in the CCD PWB. Differential amplification is made for the signal output (OS) and the compensation output (DOS).

Shift electrode

To Shift register

Accumulation electrode

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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. The analog signal inputted to the AD convertor is converted into 8bit digital data and passed to the PCU PWB. The machine employs the TCD1501C as the image sensor. The TCD1501C is the reduction type high sensitivity CCD linear sensor of one-output system. 5000 pixels of 7um x 7um are arranged in line to allow scanning of A3 document at 400dpi (16 lines/mm).

Operation section

(1) Outline

The operation circuit is composed of the key matrix circuit and the display matrix circuit.

(2) Key matrix circuit

The CPU in the MCU sends select signals SELIN1 - 3 to the selector in the operation circuit. The signals detects ON/OFF of the key and are sent to the CPU as KIN1 - 2.

Operation circuit

MCU

+5V

Selector

CPU

(3) Display circuit section

The display is controlled by inputting the data signal and the clock signal from the CPU and the latch signal from the ASIC to the LED driver in the operation circuit.

IC902,903

Key

Operation circuit

MCU

+5V+5V

OP-CLK

CPU

OP-DATA

Display LED

LED driver

ASIC

OP-LATCH

IC901

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Sharp AL-1000, AL-1010 Service Manual. Parts Guide

Specifications and Main Features

Frequently Asked Questions

User Manual