Sharp AL-2040CS, AL-2030 Service Manual. Parts Guide

SERVICE MANUAL

CODE: 00ZAL2040CS1E

DIGITAL MULTIFUNCTIONAL SYSTEM

(AL-2040CS)

AL-2030

MODEL AL-2040CS

CONTENTS

[ 1 ] GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

[ 2 ] SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1

[ 3 ] CONSUMABLE PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1

[ 4 ] EXTERNAL VIEWS AND INTERNAL STRUCTURES . . . . . . . . . 4 - 1

[ 5 ] UNPACKING AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1

[ 6 ] COPY PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1

[ 7 ] OPERATIONAL DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1

[ 8 ] DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1

[ 9 ] ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 1

[10] SIMULATION, TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . 10 - 1

[11] USER PROGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 1

[12] ELECTRICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 1

Parts marked with “ ” are important for maintaining the safety of the set. Be sure to replace these parts with specified ones for maintaining the safety and performance of the set.

This document has been published to be used

SHARP CORPORATION

for after sales service only. The contents are subject to change without notice.

CAUTION

This product is a class 1 laser product that complies with 21CFR 1040 of the CDRH standard and IEC825. This means that this machine does not produce hazardous laser radiation. The use of controls, adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure.

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 : 770 ~ 795nm Pulse times : 12.88µs ± 12.88ns/7mm Out put power : MAX 0.2m

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.

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 cover or attempt to gain access to the inside of the product. Refer all servicing to qualified personnel.

The foregoing is applicable only to the 220V model

230V model and 240V model.

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.

LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT

CONTENTS

[1] GENERAL

1. Major functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

[2] SPECIFICATIONS

1. Basic Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2. Operation specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

4. GDI Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

5. Scan function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

6. SPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

[3] CONSUMABLE PARTS

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

2. Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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

[4] EXTERNAL VIEWS AND INTERNAL STRUCTURES

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

2. Internal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

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. Copier installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

2. Cautions on handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

3. Checking packed components and accessories . . . . . . . . . . . 5-1

4. Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5. Removing protective packing materials. . . . . . . . . . . . . . . . . . 5-2

6. Installing the TD cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

7. Loading paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

8. Power to copier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

9. Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

10. Connecting the interface cable . . . . . . . . . . . . . . . . . . . . . . . . 5-4

11. Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

A. USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

B. RJ45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

12. Moving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

[6] COPY PROCESS

1. Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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

3. Actual print process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

[7] OPERATIONAL DESCRIPTIONS

1. Outline of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

2. Scanner section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

A. Scanner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

B. Optical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

C. Drive system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

3. Laser unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

A. Basic structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

B. Laser beam path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

C. Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

4. Fuser section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

A. General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

5. Paper feed section and paper transport section . . . . . . . . . . . 7-4

A. Paper transport path and general operations . . . . . . . . . . . 7-4

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

7. SPF section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

A. Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

B. Document transport path and basic composition . . . . . . . . 7-7

C. Operational descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

D. SPF open/close detection (book document detection) . . . . 7-8

[8] DISASSEMBLY AND ASSEMBLY

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

A. List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

B. Disassembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

C. Assembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

D. Charger wire cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

E. Charger wire replacement . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

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

A. List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

B. Disassembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

C. Assembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

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

A. List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

B. Disassembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

C. Assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

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

A. List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

B. Disassembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

C. Assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

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

A. List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

B. Disassembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

C. Assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

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

A. List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

B. Disassembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

C. Assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

D. Pressure plate holder attachment . . . . . . . . . . . . . . . . . . . 8-14

7. Rear frame section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

A. List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

B. Disassembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

C. Assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

8 Power section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

A. List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

B. Disassembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

C. Assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

9. SPF section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

A. SPF motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

B. Pick-up roller, paper feed roller . . . . . . . . . . . . . . . . . . . . . 8-17

C. Paper exit roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

D. Set sensor, scan front sensor . . . . . . . . . . . . . . . . . . . . . . 8-18

E. Transport roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

10. 2nd cassette section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

A. Paper sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

B. Cassette detection switch . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

C. Paper feed solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

D. Transport roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

E. Paper feed clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

F. 2nd paper feed roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

[9] ADJUSTMENTS

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

A. Copy magnification ratio adjustment . . . . . . . . . . . . . . . . . . 9-1

B. Image position adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

2. Copy density adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

A. Copy density adjustment timing . . . . . . . . . . . . . . . . . . . . . 9-4

B. Note for copy density adjustment . . . . . . . . . . . . . . . . . . . . 9-4

C. Necessary tool for copy density adjustment . . . . . . . . . . . . 9-4

D. Features of copy density adjustment . . . . . . . . . . . . . . . . . 9-4

E. Copy density adjustment procedure . . . . . . . . . . . . . . . . . . 9-4

3. High voltage adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

A. Main charger (Grid bias) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

B. DV bias check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

4. Duplex adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

A. Adjusting the paper reverse position in memory

for duplex copying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

B. Adjusting trailing edge void in duplex copy mode . . . . . . . . 9-6

5. SPF scan position automatic adjustment . . . . . . . . . . . . . . . . . 9-7

6. SPF mode sub scanning direction magnification ratio

adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

7. Automatic black level correction. . . . . . . . . . . . . . . . . . . . . . . . 9-8

[10] SIMULATION, TROUBLE CODES

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

2. List of simulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

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

4. Trouble codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17

A. Trouble codes list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17

B. Details of trouble codes. . . . . . . . . . . . . . . . . . . . . . . . . . 10-17

[11] USER PROGRAM

1. Functions that can be set with user programs . . . . . . . . . . . . 11-1

2. Toner save mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

3. User programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

[12] ELECTRICAL SECTION

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

A. Overall block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

2. Actual wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

A. AL-2030. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

B. AL-2040CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4

3. Signal name list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

[1] GENERAL

1. Major functions

Configurations

Item

CPM

Model AL-2030 20CPM 16PPM MB AL-2040CS 20CPM 16PPM MB

(Letter)

Descriptions of items

CPM: Copy speed (Copies Per Minute) PPM: Print speed (Print Per Minute) SB/MB: SB = Manual feed single bypass, MB = Manual feed multi-bypass 2 tray: Second cassette unit. SPF: Original feed unit R-SPF: Duplex original feed unit Color scanner: Color scanner function GDI printer: GDI printer function with USB. PCL printer: PCL printer function with USB. E-SORT: Electronic sort function Duplex: Auto duplex copy/print function Shifter: Job separator function FAX: FAX function.

Descriptions of table

: Standard provision : No function or no option available

Opt: Option

PPM

(Letter)

SB/MB 2 Tray SPF R-SPF

Color

Scanner

GDI

printer

PCL

printerE-SORT

Duplex Shifter RJ45 FAX

(print only)

AL-2030

AL-2040CS GENERAL 1 - 1

AL-2040C

[2] SPECIFICATIONS

1. Basic Specifications

Item Ty pe D es k to p Copy system Dry, electrostatic Segment (class) Digital personal copier Copier dimensions AL-2030 20-1/2" (W) x 17-5/8" (D) x 14-1/8" (H) (518mm (W) x 445mm (D) x 358mm (H))

AL-2040CS 20-1/2" (W) x 17-5/8" (D) x 17-5/8" (H) (518mm (W) x 445mm (D) x 445mm (H))

Weight (Approximately) AL-2030 37.9 lbs. (17.2Kg) TD cartridge not included

AL-2040CS 45.9 lbs. (20.8Kg)

2. Operation specifications

Section, item Details

Paper feed section

Paper exit section Exit way Face down

Originals Original set Center Registration (left edge)

Optical section

Paper feed system

Inch system

AB system Tray paper feed

Scanning section

Writing section

Tray paper feed section

Multi-bypass paper feed section

section

Multi-bypass paper feed section

Capacity of output tray 100 sheets

Max. original size 8-1/2" x 14" (A4) Original kinds sheet, book Original size detection None Scanning system 3 CCDs (RGB) sensor scanning by lighting white

CCD sensor Resolution 600 dpi Lighting lamp Type CCFL

Output data Output: R, G, B 1 or 8 bits/pixel / Input: A/D 16 bits

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

AL-2030 1 tray (250 sheet) + multi-bypass (50 sheet) AL-2040CS 2 tray (500 sheet) + multi-bypass (50 sheet) Paper size 8-1/2" x 14", 8-1/2 x 11", 8-1/2" x 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 8-1/2" x 14", 8-1/2 x 11", 8-1/2" x 5-1/2",

Paper weight 15 - 34.5 lbs. Paper feed capacity 50 sheets Kinds Standard paper, specified paper, recycled paper,

Remark User adjustment of paper guide available 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 56 - 128g/m Paper feed capacity 50 sheets Kinds Standard paper, specified paper, recycled paper,

Remark User adjustment of paper guide available

Voltage 560Vrms Power consumption 2.8W

3-1/2" x 5-1/2" (Landscape)

OHP, Label, Envelop (Single copy)

(15 - 21 lbs.)

(15 - 34.5 lbs.)

OHP, Label, (Single copy)

lamp

(12 bits actual)

AL-2040CS SPECIFICATIONS 2 - 1

Section, item Details

Image forming Photoconductor Type OPC (30ø)

Life 18k

Charger Charging system Saw-tooth charging with a grid, / (-) scorotron

discharge Transfer system (+) DC corotron system Separation system (-) DC corotron system

Developing Developing system Dry, 2-component magnetic brush development

system

Cleaning Cleaning system Counter blade system (Counter to rotation)

Fusing section Fusing system Heat roller system

Upper heat roller Type Teflon roller Lower heat roller Type Silicon rubber roller Heater lamp Type Halogen lamp

Voltage 120V Power consumption 800W

Electrical section Power source Voltage 120V

Frequency Common use for 50 and 60Hz

Power consumption Max. Less than 1000W

Average (during copying) 350Wh/H Average (stand-by) 80Wh/H Pre-heat mode 25Wh/H Auto power shut-off mode 8.8W or less

3. Copy performance

Section, item Details AL-2030 AL-2040CS

Copy magnification Fixed

magnification ratios

Zooming magnification

ratios Manual steps (manual, photo) 5 steps Copy speed First-copy time *1

Inch system 8-1/2" x 11" (Landscape)

AB system A4 (Landscape)

AB system B5 (Landscape)

Max. continuous copy quantity 99 Void Void area Leading edge 1 - 4mm

Warm-up time 0 sec. Immediately the ready lamp is lit. Power save mode reset time 0 sec. Immediately the ready lamp is lit. Paper jam recovery time 0 sec.

*1: The first-copy time is measured after the power save indicator turns off following power on, using the document glass with the polygon

rotating in the copy ready state and "Selection of copy start state" set to ON in the user programs (8-1/2" x 11" (A4), paper fed from paper tray).

The first-copy time may vary depending on machine operating conditions and ambient conditions such as temperature.

(Approximately)

Copy speed

(CPM)

Copy speed

(CPM)

Copy speed

(CPM)

Image loss Leading edge same size: 3.0mm or less (OC) / 4mm or less (SPF/Duplex)

Same size 20 20 Enlargement 20 20 Reduction 20 20 Same size 20 20 Enlargement 20 20 Reduction 20 20 Same size 20 20 Enlargement 20 20 Reduction 20 20

Trailing edge 4mm or less Side edge

void area

4 Reduction + 3 Enlargement (AB system: 50, 70, 86, 100, 141, 200%) (Inch system: 50, 64, 78, 100, 129, 200%)

25 - 400% (376 steps in 1% increments) 50 - 200% when using SPF

8.0 seconds (When user program 24 is set to OFF)

10.7 seconds (When user program 24 is set to ON) (paper: 8-1/2" x 11" (A4), exposure mode: AUTO, copy ratio: 100%)

0.5mm or more (per side)

4.5mm or less (total of both sides)

Enlarge: 1 - 5mm or less (OC) / 3mm or less (SPF/Duplex) Reduction (50%): 6.0mm or less (OC) / 8mm or less (SPF/Duplex)

∗ Jam recovery condition: Recovery time from 60 sec of door open.

AL-2040CS SPECIFICATIONS 2 - 2

4. GDI Printer

Print speed Max. 20ppm (excluding bypass tray, paper size A4, 8.5" x 11") (Variable depending on the PC

Duplex Yes (AL-2040CS only) Memory 8MB (Duplex model: 16MB) Interface USB 2.0 (Full speed) / (RJ45 (10Base-T) AL-2040CS only) Network Built-in NIC (AL-2040CS only) Emulation GDI Resolution 600dpi *1 Supported OS Win 98 / Me / 2000 / XP / Vista *2 WHQL support Yes *2

*1: Engine Resolution *2: By running change

performance)

5. Scan function

Type Flat Bed Color Scanner Scanning system Original table/SPF Light source 3 CCDs (RGB) sensor scanning by lighting white lamp (2 pcs of CCFL) Resolution Optical: 600 x 600dpi

Originals Sheet type / Book type Output data R, G, B 1 or 8 bits/pixel Scan range OC / SPF: 8.5" (H) x 14.0" (V)

Scan speed OC / SPF: Max. 2.88ms/line Protocol TWAIN / WIA (Only XP) / STI Interface USB2.0 (Full speed support) Scanner utility Button Manager / Sharpdesk / Composer Scan key/lamp Yes Duplex scan No Supported OS Win 98 / Me / 2000 / XP / Vista *1 Void area No (User settable by PC) WHQL supported Yes *1

*1: By running change

Setting range: 50 - 9600dpi (Preview resolution is fixed at 75dpi)

Original position: Left Center

6. SPF

Original capacity 50 sheets (14 to 23.9 lbs.) (56 to 90g/m Original size 8-1/2" x 14" to 5-1/2" x 8-1/2" / A4 to A5 (Landscape) Original replacement speed Max. 14 sheets (70%) Original placement Face up Original weight 14 - 23.9lbs. (56 to 90g/m Mixed feeding (Paper size) No Original which cannot Thermal papers, originals with punch holes for files, be used folded paper, transparent originals such as

OHP films, stapled or clip used originals with cover up liquid used, Originals with tape sealed, originals

with high level frictional coefficient such as photos or catalogs.

)

) Stacking Height: less than 6.5mm or 1/4"

AL-2040CS SPECIFICATIONS 2 - 3

[3] CONSUMABLE PARTS

1. Supply system table

Common to all destinations

No. Name Content Life Product name Package

1 Develop cartridge (Black) x 1 Toner/developer cartridge x 1

(Toner: Net weight 213g) (Developer: Net weight 190g)6K(5% document)

2 Develop cartridge (Black) x 1 Toner/developer cartridge x 1

(Toner: Net weight 124g) (Developer: Net weight 190g)4K(5% document)

3 Drum cartridge Drum cartridge 18K AL-100DR 5

2. Environmental

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

AL-100TD 5

AL-110TD 5

(1) Normal operating condition

Temperature: 20 - 25°C Humidity: 65 ± 5%RH

(2) Acceptable operating condition

Humidity (RH)

85%

60%

20%

10˚C 30˚C 35˚C

(3) Transport condition

Humidity (RH)

90%

(4) Supply storage condition

Humidity (RH)

90%

20%

–5˚C 45˚C

60%

15%

–25˚C 30˚C 40˚C

AL-2040CS CONSUMABLE PARTS 3 - 1

3. Production control number (lot No.) identification

Production month Production day Destination code (Dealer, distributor, OEM, etc.) Production place (SOCC: Fixed to B.) End digit of year Version No.

∗ Destination

Division No.

EX Destination A same pack G

B same pack H

Option Destination A P

The label on the drum cartridge shows the date of production. (SOCC production)

Production month Production day Destination code (Dealer, distributor, OEM, etc.) Production place (SOCC: Fixed to B.) End digit of year Version No.

Production control label attachment position

Production control label attachment position(*1)

Division No. Ex production 1 Option 2 Same pack 3

X000119Ver.A 1

Production month (1 - 9 = Jan. - Sep. 0 = Oct. X = Nov. Y = Dec.) Serial number of month Fixed to 1. Pack division (See table below) End digit of year Version No.

*1: The production control label is not attached to the cartridge of

a China product.

AL-2040CS CONSUMABLE PARTS 3 - 2

[4] EXTERNAL VIEWS AND INTERNAL STRUCTURES

4 5

1. Appearance

SPF

Exit area

1 2

3 4

1 Document glass 2 Operation panel 3 Front cover 4 Paper tray 1 5 Paper tray 2 (AL-2040CS only) 6 Multi-bypass tray

7 Side cover 8 Side cover open button 9 Bypass tray paper guides 10 Paper output tray 11 Paper output tray extension 12 Power switch 13 Handle 14 Power cord

Document feeder tray

Original guide

Document feeder cover

Peep hole

Interface

LAN connector

USB connector

7 8

(AL-2040CS only)

10 11

12 13 14

2. Internal

TD cartridge Drum cartridge

1 Front cover 2 Side cover 3 Fusing unit release lever

4 Transfer charger 5 Charger cleaner

AL-2040CS EXTERNAL VIEWS AND INTERNAL STRUCTURES 4 - 1

3. Operation panel

1234567 89 10 11 12 13

14 15 16 17 18

1 Original to copy key and indicators (AL-2040CS only) 2 Exposure mode selector key and indicators

Two-sided copies from one-sided originals. Turn on Long Edge or Turn on Short Edge can be selected.

3 Light and dark keys and indicators

Use to adjust the MANUAL or PHOTO exposure level. Selected exposure level is shown by a lit indicator. Use to start and terminate user program setting.

5 SPF indicator 6 SPF misfeed indicator 7 Copy ratio selector key and indicators

Use to sequentially select preset reduction/enlargement copy ratios. Selected copy ratio is shown by a lit indicator.

9 Display

Displays the specified copy quantity, zoom copy ratio, user program code, and error code.

11 ONLINE key and indicator

Lights up when the unit is used as a printer and scanner (AL- 2040CS only). *3

13 Power save indicator

Lights up when the unit is in a power save mode.

15 Paper feed location indicators

Light up to show the selected paper feed station.

17 Copy quantity keys

• Use to select the desired copy quantity (1 to 99).

• Use to make user program entries.

*1: Drum cartridge replacement

The useful life of the drum cartridge is approximately 18,000 copies*. When the internal counter reaches approximately 17,000 copies, the drum replacement required ( ) indicator will light up indicating that replacement of the drum cartridge will be needed soon. For more information on purchasing the drum cartridge, please refer to the Operation Manual. When the indicator begins to blink, the unit will stop operating until the cartridge is replaced. Replace the drum cartridge at this time.

*: Based on copying onto letter size paper at 5% toned area.

*2: TD cartridge replacement

The TD cartridge replacement required ( ) indicator will light up when toner is needed. For more information on purchasing the TD cartridge. If copying is continued while the indicator is lit, copies will gradually become lighter until the unit stops and the indicator begins blinking.

Use to sequentially select the exposure modes: AUTO, MANUAL or PHOTO. Selected mode is shown by a lit indicator.

4 Alarm indicators

8 Copy ratio display (%) key

10 SCAN key and indicator (AL-2040CS only) *3, *4

12 Start key and indicator

14 Tray select key

16 ZOOM keys and indicator

18 Clear key

Drum replacement required indicator *1 Misfeed indicator TD cartridge replacement required indicator *2

• Use to verify a zoom setting without changing the zoom ratio.

• Use to check the number of originals that must be returned to the document feeder tray if an original misfeed occurs while using the SPF.

• Copying is possible when the indicator is on.

• Press to start copying

• Use to set a user program.

Use to select a paper feed station (paper tray 1, paper tray 2 (AL-2040CS only) or multi-bypass tray).

Use to select any reduction or enlargement copy ratio from 25% to 400% in 1% increments. (When the SPF is being used, the zoom copy ratio range is 50% to 200%.)

• Press to clear the display, or press during a copy run to terminate copying.

• Press and hold down during standby to display the total number of copies made to date.

*3: Indicators on the operation panel

The ONLINE indicator and the start ( ) indicator indicate the state of the printer or scanner.

SCAN indicator

ONLINE indicator

Start indicator

On: Indicates the unit is ready for copying or scanning is

being performed.

Blinking: The indicator blinks in the following situations:

• When a print job is interrupted.

• When reserving a copy job.

• When toner is being replenished during a copy or print job.

Off: The indicator is off in the following situations:

• During copying or scanning.

• The unit is in the auto power shut-off mode.

• When a misfeed or error has occurred.

Start indicator

Power save indicator

AL-2040CS EXTERNAL VIEWS AND INTERNAL STRUCTURES 4 - 2

ONLINE indicator

The ONLINE key is pressed and on line and off line are changed.

On: Indicates the unit is ready for printing or scanning is

being performed. (On line) Blinking: Printing or data is being received from a computer. Off: Copying is being performed. (Off line)

Power save indicator

On: Indicates the unit is in a power save mode. Blinking: Indicates that the unit is initializing (when the side

cover is opened and closed or the power turned off

and on).

SCAN indicator (AL-2040CS only)

On: The SCAN ( ) key has been pressed and the unit

is in scanner mode. Blinking: A scan job is being executed from the computer, or

scan data is stored in the unit’s memory. Off: The unit is in the copy mode.

*4: Using the SCAN key to begin scanning

Note:

• Scanning is not possible during a copy job.

• If the SCAN ( ) key is pressed during a print job, the scan

job will be stored.

• When scanning an original that has been placed in the SPF,

only one original can be placed unless you are using Sharpdesk.

1) Press the SCAN ( ) key.

The unit enters scan mode.

2) Place the original you wish to scan on the document glass/

SPF.

3) Press the right copy quantity key to display the number of

the application that you wish to use for scanning. The application numbers are initially as follows.

Application

number

Application launched

SC1 Sharpdesk (Full color) (if installed) SC2 Sharpdesk (Monochrome) (if installed) SC3 E-mail (your standard e-mail program in

the Windows OS you are using) SC4 Fax (if a fax program is installed) SC5 OCR (if an OCR program is installed) SC6 Microsoft Word (if installed)

4) Press the start ( ) key. Scanning will start and the scanned data will be transferred

to the application.

AL-2040CS EXTERNAL VIEWS AND INTERNAL STRUCTURES 4 - 3

4. Motors and solenoids

No. Part name Control signal Function / Operation

1 Main motor MM Drives the copier. 2 Scanner motor MRMT Drives the optical mirror base (scanner unit). 3 Toner motor TM Supplies toner. 4 Cooling fan motor VFM Cools the optical, fusing section. 5 Resist roller solenoid RRS Resist roller rotation control solenoid 6 Paper feed solenoid CPFS1 Cassette Paper feed solenoid 1 7 Multi paper feed solenoid MPFS Multi manual pages feed solenoid 8 SPF motor SPFM Drives the single pass feeder 9 Duplex motor DMT Devices the duplex paper transport section

10 Paper feed solenoid CPFS2 Cassette Paper feed solenoid 2

AL-2040CS EXTERNAL VIEWS AND INTERNAL STRUCTURES 4 - 4

5. Sensors and switches

No. Name Signal Type Function Output

1 Scanner unit home position

sensor 2 POD sensor POD Transmission sensor Paper exit detection "H" at paper pass 3 PPD2 sensor PPD2 Transmission sensor Paper transport detection 2 "L" at paper pass 4 Cassette detection switch CED1 Micro-switch Cassette installation detection "H" at cassette insertion 5 PPD1 sensor PPD1 Transmission sensor Paper transport detection 1 "L" at paper pass 6 Door switch DSW Micro-switch Door open/close detection

7 Drum reset switch DRST Micro-switch New drum detection switch Instantaneously "H" at

8 SPF sensor SPID/

9 SPPD sensor SPPD Transmission sensor Paper transport detection "L" at paper pass

10 2nd cassette DSW Micro-switch 2nd cassette door open detection 1 or 0V of 5V at door open 11 PPD3 sensor PPD3 Transmission sensor Paper transport detection 3 "L" at paper pass

MHPS Transmission sensor Scanner unit home position detection "H" at home position

(safety switch for 24V)

Transmission sensor Paper entry detection

SD SW

Cover open/close detection

1 or 0V of 24V at door open

insertion of new drum "L" at paper pass

AL-2040CS EXTERNAL VIEWS AND INTERNAL STRUCTURES 4 - 5

6. PWB unit

No. Name Function

1 Exposure lamp invertor PWB Exposure lamp (CCFL) control 2 Main PWB (MCU) Copier control 3 Operation PWB Operation input/display 4 High voltage PWB 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 9 NIC PWB Network print control (AL-2040CS only)

10 Power PWB AC power input, DC voltage control

AL-2040CS EXTERNAL VIEWS AND INTERNAL STRUCTURES 4 - 6

7. Cross sectional view

No. Part name Function and operation

1 Scanner unit Illuminates the original with the copy lamp and passes the reflected light to the lens unit(CCD). 2 Exposure lamp Exposure lamp (CCFL) Illuminates original 3 LSU (Laser unit) Converts the original image signal into laser beams and writes onto the drum. 4 Paper exit roller Roller for paper exit 5 Main charger Provides negative charges evenly to the drum surface. 6 Heat roller Fuses toner on the paper. (Teflon roller) 7 Pressure roller Fuses toner on the paper. (Silicon rubber roller) 8 Drum Forms images. 9 Transfer unit Transfers images onto the drum.

10 Pickup roller Picks up the manual feed paper. (In multi feed only) 11 Manual paper feed tray Tray for manual feed paper 12 Manual paper feed roller Transport the paper from the manual paper feed port. 13 PS roller unit Takes synchronization between the lead edge and the rear edge of the paper. 14 Paper feed roller Picks up a sheet of paper from the cassette. 15 Pickup roller Picks up documents. 16 Separation roller Separates documents to feed properly. 17 PS roller Feeds documents to the scanning section. 18 Paper exit roller Discharges documents.

AL-2040CS EXTERNAL VIEWS AND INTERNAL STRUCTURES 4 - 7

[5] UNPACKING AND INSTALLATION

1. Copier installation

Improper installation may damage the copier. Please note the following during initial installation and whenever the copier is moved.

Caution: If the copier is moved from a cool place to a warm place,

condensation may form inside the copier. Operation in this condition will cause poor copy quality and malfunctions. Leave the copier at room temperature for at least 2 hours before use.

Do not install your copier in areas that are:

• damp, humid, or very dusty

• exposed to direct sunlight

2. Cautions on handling

Be careful in handling the copier as follows to maintain the performance of this copier.

Do not drop the copier, subject it to shock or strike it against any object.

Do not expose the drum cartridge to direct sunlight. Doing so will damage the surface (green portion) of the drum car-

tridge, causing poor print quality.

• poorly ventilated

• subject to extreme temperature or humidity changes, e.g., near an air conditioner or heater.

The copier should be installed near an accessible power outlet for easy connection.

Be sure to connect the power cord only to a power outlet that meets the specified voltage and current requirements.

Also make certain the outlet is properly grounded. Be sure to allow the required space around the machine for servic-

ing and proper ventilation.

8" (20cm)

Store spare supplies such as drum cartridges and TD cartridges in a dark place without removing from the package before use.

If they are exposed to direct sunlight, poor print quality may result. Do not touch the surface (green portion) of the drum cartridge. Doing so will damage the surface of the cartridge, causing poor

print quality.

3. Checking packed components and accessories

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

Operation manual

Software CD-ROM

Drum cartridge (installed in unit)

(10cm)

4" (10cm)

AL-2040CS UNPACKING AND INSTALLATION 5 - 1

TD cartridge

4. Unpacking

Be sure to hold the handles on both sides of the unit to unpack the unit and carry it to the installation location.

5. Removing protective packing materials

1) Remove all pieces of tape shown in the illustration below.

Then open the SPF and remove protective materials. After that, take out the bag containing the TD cartridge.

AL-2040CS

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.

Protective pins

CAUTION tape

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

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. Hold the tab of the protective cover and pull the tab to your side to remove the cover.

4 or 5 times

AL-2030

2) Release the scan head locking switch. The scan head locking switch is under the document glass. If the switch is locked ( ), the unit will not operate. Unlock the

switch ( ) as shown below.

Grasp here and turn in the direction of the arrow.

(A)

Lock Unlock

To lock the scan head locking switch, hold up the catch in illustration (A) and turn the center knob counter-clockwise 90 degrees until you hear a click.

6. Installing the TD cartridge

1) Open the multi-bypass tray, and then open the side cover.

5) Gently insert the TD cartridge until it locks in place while pushing the lock release button.

Lock release button

6) Close the front cover and then the side cover by pressing the round projections near the side cover open button.

Caution: When closing the covers, be sure to close the front cover

securely and then close the side cover. If the covers are closed in the wrong order, the covers may be damaged.

AL-2040CS UNPACKING AND INSTALLATION 5 - 2

7. Loading paper

1) Raise the handle of the paper tray and pull the paper tray out until it stops.

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). To store the pressure plate lock, rotate the lock to fix it on the relevant location.

Pressure plate lock

4) Adjust the paper guides on the paper tray to the copy paper width and length. Squeeze the lever of paper guide (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 paper and insert it into the tray. Make sure the edges go under the corner hooks.

Note: Do not load paper above the maximum height line ( ).

Exceeding the line will cause a paper misfeed.

6) Gently push the paper tray back into the unit.

Paper guide (A)

8. Power to copier

Ensure that the power switch of the unit is in the OFF position. Plug the other end of the power cord into the nearest outlet. Turn the power switch on the left side of the unit to the "ON" position. The start ( ) indicator will light up and other indicators which show the initial settings of the operation panel will also light up to indicate the ready condition.

9. Software

The CD-ROM that accompanies the machine contains the following software:

Printer driver (AL-2030)

The printer driver enables you to use the printer function of the machine.

The printer driver includes the Print Status Window. This is a utility that monitors the machine and informs you of the printing status, the name of the document currently being printed, and error messages.

Please note that the printing over a network connection is not possible.

MFP driver (AL-2040CS)

Printer driver

The printer driver enables you to use the printer function of the machine.

Please note that the Print Status Window does not operate when the machine is used as a network printer.

Scanner driver*

The scanner driver allows you to use the scanning function of the machine with TWAIN-compliant and WIA-compliant applications.

Sharpdesk* (AL-2040CS)

Sharpdesk is an integrated software environment that makes it easy to manage documents and image files, and launch applications.

Button Manager* (AL-2040CS)

Button Manager allows you to use the scanner menus on the machine to scan a document.

*: The scanning feature can only be used with computers that are

connected to the machine by a USB cable. If you are connected to the machine by a LAN connection, only the printer function can be used.

Before installation

Hardware and software requirements

Check the following hardware and software requirements in order to install the software.

Computer type

Operating system*

Display 800 x 600 dots (SVGA) display with 256 colors

Hard disk free space

Other hardware requirements

IBM PC/AT or compatible computer equipped with a USB 2.0/1.1*

Windows 98, Windows Me, Windows 2000

2 *3

Professional* Windows XP Home Edition*

(or better) 150 MB or more

An environment on which any of the operating systems listed above can fully operate

or 10Base-T LAN interface

, Windows XP Professional*4,

AL-2040CS UNPACKING AND INSTALLATION 5 - 3

*1: Compatible with Windows 98, Windows Me, Windows 2000

Professional, Windows XP Professional or Windows XP Home Edition preinstalled model standardly equipped with a USB port.

*2: Printing is not available in MS-DOS mode. *3: The machine does not support printing from a Macintosh envi-

ronment.

*4: Administrator's rights are required to install the software using

the installer.

Installation environment and usable software

The following table shows the drivers and software that can be installed for each version of Windows and interface connection method.

Cable

USB Windows 98/

LAN Windows 98/

*1: The printer driver that is installed will vary depending on the

*2: Although it is possible to install Button Manager and Sharp-

Install the software according to the Operation Manual.

Operating

system

Me/2000/XP

type of connection between the machine and your computer.

desk on Windows 98/Me/2000/XP, neither Button Manager nor the scanner function of Sharpdesk can actually be used.

Printer

driver

Available*

Scanner

driver

Button

Manager

Available

Not Available*

Sharpdesk

10. Connecting the interface cable

Connecting a USB cable

Follow the procedure below to connect the machine to your computer.

A USB cable for connecting the machine to your computer is not included with the machine. Please purchase the appropriate cable for your computer.

Caution:

• USB is available with a PC/AT compatible computer that was

originally equipped with USB and had Windows 98, Windows Me, Windows 2000 Professional, Windows XP Professional or Windows XP Home Edition preinstalled.

• Do not connect the USB cable before installing the printer driver.

The USB cable should be connected during installation of the printer driver.

1) Insert the cable into the USB connector on the machine.

1) Insert the LAN cable into the LAN connector on the machine. Use a network cable that is shielded.

2) Turn on the machine.

3) Set up according to the Operation Manual.

11. Interface

A. USB

Connector

4-pin ACON UBR23-4K2200 Type-B connector

Cable

Shielded twisted pair cable (2 m (6 feet) Max.: high-speed transmission equivalent)

Pin configuration

The pin numbers and signal names are listed in the following table.

Pin No. Signal name

1+5V 2-DATA 3+DATA 4GND

2) Insert the other end of the cable into your computer’s USB port.

Using the machine as a network printer (AL-2040CS only)

Note:

• Interface cables for connecting the machine to your computer

are not included with the machine. Please purchase the appropriate cable for your computer.

• If you intend to use the machine as a scanner, it must be con-

nected to your computer with a USB interface cable. The scanner function cannot be used if the machine is connected with a LAN cable.

AL-2040CS UNPACKING AND INSTALLATION 5 - 4

B. RJ45

RJ-45 connector pin arrangement

Pin No. Signal name LAN adapter RJ-45 connector

1 TD+ Send output + 2 TD– Send output 3 RD+ Receive input + 6 RD– Receive input -

4, 5, 7, 8 Not used. Not used.

12. Moving

Moving instructions

When moving the unit, follow the procedure below. Note: When moving this unit, be sure to remove the TD cartridge

in advance.

1) Turn the power switch off and remove the power cord from the outlet.

2) Open the side cover and front cover, in that order. Remove the TD cartridge and close the front cover and side cover, in that order.

To open and close the side cover and front cover, and to remove the TD cartridge.

3) Raise the handle of the paper tray and pull the paper tray out until it stops.

4) Push the center of the pressure plate down until it locks in place and lock the plate using the pressure plate lock which has been stored in the front of the paper tray.

5) Push the paper tray back into the unit.

6) Lock the scan head locking switch.

Note: When shipping the unit, the scan head locking switch must

be locked to prevent shipping damage.

7) Close the multi-bypass tray and the paper output tray extension, and attach the packing materials and tape which were removed during installation of the unit.

8) Pack the unit into the carton.

AL-2040CS UNPACKING AND INSTALLATION 5 - 5

[6] COPY PROCESS

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

1. Functional diagram

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

Main charger

(Basic operation cycle)

Laser beam

MG roller

Main high voltage unit

Saw tooth

Cleaning blade

Drum

Transfer unit

Resist roller

Semiconductor laser

Focus correction lens

Exposure

Charge

To face down tray

Cleaning blade

Waste toner box

Paper release Fusing

Heat roller

Heater lamp

Drum

Cleaning

Separation

Electrode

AL-2040CS COPY PROCESS 6 - 1

Transfer

Transfer charger

Transfer high voltage unit

Developing

Cassette

paper feed

Synchronization

with drum

Toner

Developer

PS roller

Manual feed

Print pr ocess

Paper transport route

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 transferred 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.

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.

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.

Semiconductor laser

Exposure (semiconductor laser)

OPC layer

Pigment layer

Aluminum drum

Drum surface charge after the exposure

OPC layer

Pigment layer

Aluminum

Non-image area Image area

layer

About

DC5.5KV

( 580V/ 400V)

AL-2040CS COPY PROCESS 6 - 2

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-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.

About DC 5.2kV

400V 8V

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

MG roller

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.

AL-2040CS COPY PROCESS 6 - 3

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 eliminate 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 laser

Charge by the Scorotron charger

Function

The Scorotron charger functions to maintain uniform surface potential on the drum at all times, It 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.

Start

1) Because the grid potential is at a low level, the drum potential 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 photoconductor potential is switched from LOW to HIGH.

3) Once developing bias (-400V) is applied and the photo conductor 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. Therefore, carrier will not make a deposit on the drum surface.

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 attract potential

Low

High

Print potential

Developing bias

Drum potential

Time

AL-2040CS COPY PROCESS 6 - 4

[7] OPERATIONAL DESCRIPTIONS

1. Outline of operation

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

(Basic configuration)

Scanner section

Operation

section

MCU (Main control/image process section)

CCD

NIC PWB

Network

(print only)

LSU (Laser unit) Laser diode, Polygon mirror lens

Laser beam

Process section

Printer section

Cassette paper

feed section

Paper exit

(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.

USB

Fusing section

Paper transport section

Manual paper

feed section

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.

(Outline of printer operation)

The print data sent from the PC are passed through the NIC PWB (in case of network connection) and the MCU to the LSU. The procedures after that are the same as above 5) and later.

(Outline of scanner operation)

The scan data are passed through the MCU to the PC according to the conditions requested by the operations with the operation panel.

AL-2040CS OPERATIONAL DESCRIPTIONS 7 - 1

2. Scanner section

A. Scanner unit

The scanner unit in the digital copier scans images. It is composed of the optical unit and the drive unit. The optical unit

performs scanning in the main scan direction with the light receiving elements (color CCD). The drive unit performs scanning in the sub scanning direction by moving the optical unit.

B. Optical system

Two white lamps are used as the light source. Light radiated from the light source is applied to the document on

the document table. The reflected light from the document is reflected 4 times by No. 1 - No. 3 mirrors and passed through the reduction lens to form images on the light-receiving surface of 3line CCD.

The light-receiving surface of the color CCD is provided with 3 line scanning sections for RGB. Separate images scanned in each color section are overlapped to complete color scanning. (When PC scanning)

The resolution is 600dpi. When copying, only the green component is used to print with the

printer. The color component for printing can be switched to red or blue by

the service simulation.

100

Sensitivity

380

45.4

480

(Spectrum characteristics of the lamp)

100.0

580

Wavelength [nm]

50.2

680

Spectral sensitivity characteristics (Standard characteristics)

Relative sensitivity

Wavelength [nm]

(Spectrum characteristics of the color CCD)

89 98

780

3 4 2

(Optical unit)

1 Table glass 2 Optical unit 3 Lens 4 Mirror 1 5 Mirror 2 6 Mirror 3 7 CCD PWB 8 Lamp 9 Reflector

10 Original

C. Drive system

The drive system is composed of the scanner motor, the pulley gear, the idle pulley, the idle gear, the belt 473, the belt 190, and the shaft.

The motor rotation is converted into reciprocated movements of the belt 473 through the idle gear, the pulley gear, the belt 190, and the idle pulley to drive the optical unit.

34 6 285

1 Scanner motor 2 Pulley gear 3 Idle pulley 4 Belt 473 5 Belt 190 6 Optical unit 7 Shaft 8 Idle gear 9 Table glass

AL-2040CS OPERATIONAL DESCRIPTIONS 7 - 2

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.

A. Basic structure

The LSU unit is the writing section of the digital optical system. The semiconductor laser is used as the light source, and images

are formed on the OPC drum by the polygon mirror and fθ 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 BD PWB works for measurement of the laser writing start point.

No Component Function

1 Semiconductor laser Generates laser beams. 2 Collimator lens Converges laser beams in parallel. 3 Cylinder lens Takes the focus. 4 Polygon mirror,

polygon motor

5 BD (Lens, PWB) Detects start timing of laser

6fθ lens Converges laser beams at a spot on

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

Reflects laser beams at a constant rpm.

scanning.

the drum. Makes the laser scanning speeds at

both ends of the drum same as each other. (Refer to the figure below.)

B. Laser beam path

C. 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: 0.18 ± 0.01mW (Laser wavelength 770 -

795nm) Polygon motor section: Brushless motor 20.787rpm

No. of mirror surfaces: 5 surfaces

4. Fuser section

a ≠ b ≠ c

ab c

d = e = f

def

fθ LENS

AL-2040CS OPERATIONAL DESCRIPTIONS 7 - 3

A. General description

General block diagram (cross section)

Separator pawl

Paper guide

Thermistor

Top v iew

Heat roller

Thermal fuse

Heat roller

Thermistor

PPD2

Separator pawl

Pressure rolle

Thermal fuse

Heater lamp

2) The surface temperature of the upper heat roller is set to 160 200°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.

(4) Fusing resistor

This model is provided with a fusing resistor in the fusing section to improve transfer efficiency.

Since the upper heat roller is conductive, when using copy paper that contains moisture and the distance between the transfer unit and the fusing unit is short, the transfer current may find a path to ground via the copy paper, the upper heat roller and the discharging brush.

5. Paper feed section and paper

transport section

A. Paper transport path and general operations

Separator pawl

(1) Heat roller

A Teflon 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.

(2) 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.

(3) 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)

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

54 3

8 9 10

11121314

1 Scanner unit 8 Drum 2 Copy lamp 9 Transfer unit 3 LSU (Laser unit) 10 Pickup roller 4 Paper exit roller 11 Manual paper feed tray 5 Main charger 12 Manual paper feed roller 6 Heat roller 13 PS roller unit 7 Pressure roller 14 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 allows you to install or remove the tray from the front cabinet.

The general descriptions on the tray paper feed and the manual paper feed operation are given below.

Triac (in the power supply unit)

Level of the thermistor is controlled by the main PWB.

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

AL-2040CS OPERATIONAL DESCRIPTIONS 7 - 4

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