SHARP AL-2040CS, AL-2030 Service Manual

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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

(1) 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.

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

PFS

RRS

OFF

3) After about 0.1 sec from when the main motor start rotating, the tray paper feed solenoid (PFS) turns on for 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.

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, 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.

PFS

RRS

OFF

PFS

RRS

OFF

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

AL-2040CS OPERATIONAL DESCRIPTIONS 7 - 5

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.

(2) 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 engaged with 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 take-up 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 allow synchronization with the lead edge of the image on the OPC drum. From this point, the operation is the same as the paper feed operation from the tray. (Refer to 7-5 - 8.)

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

MPFS

AL-2040CS OPERATIONAL DESCRIPTIONS 7 - 6

MPFS

(3) Conditions of occurrence of paper misfeed

a. When the power is turned on:

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

b. Copy operation

a PPD1 jam PPD1 does not turn off within 4 sec after

turning on the resist roller.

b PPD2 jam PPD2 is off immediately after turning on the

resist roller. PPD2 does not turn off within 1.2 sec after

turning off the resist roller.

c POD jam POD does not turn on within 2.9 sec after

turning on the resist roller. POD does not turn off within 1.5 sec - 2.7 sec

after turning off PPD2.

6. 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 micro-switch (process detection switch) installed to the machine sensor cover, making a judgement as a new drum.

Gear 20T

2) When the detection gear 38T 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

Gear 38T

Process detection switch

Projection

Gear pawl

7. SPF section

A. Outline

The SPF (Single Path Feeder) is installed to the AL-2030/2040CS as a standard provision, and it automatically copies up to 50 sheets of documents of a same size. (Only one set of copies)

B. Document transport path and basic

composition

19 3 4

1 Pickup roller 2 Sheet of document for

3 Set detection ACT 4 Document feed roller 5 Separation sheet 6 Paper entry sensor 7 PS roller D 8 Transport follower roller 9 Paper exit roller 10 Paper exit follower roller

11 Document tray

AL-2040CS OPERATIONAL DESCRIPTIONS 7 - 7

210 6 7

paper feed

C. Operational descriptions

Document set

SPID ON

Document feed unit lamp ON

PSW ON

(Copier side)

MM rotation

CPFS ON

PPD ON

RRC ON

(Transfer)

(Fusing)

POD ON

(Paper exit)

In the zooming mode, the magnification ratio in the sub scanning direction (paper transport direction) is adjusted by changing the document transport speed.

PSW

MRMT

SPF M

SPPD

SCANST

MAIN M

CPFS1

RRS

PPD1

PPD2

POD

MRMT rotation

Main motor rotation

Paper feed

Synchronization

Paper transport

Document set sensor

Copy start

The scanner is shifted to the exposure position.

(SPF side)

SPFM rotation

SPPD ON

(Exposure)

(Document exit)

SPF motor rotation

Document transport sensor

Document transport

260ms 182ms

SPF JAM generation condition

1) When SPPD is ON (document remaining) in initializing

2) When SPPD is not turned ON within about 1.5 sec (at 100% copy) after starting the document feed operation.

3) When SPPD is not turned OFF within about 4.7 sec (at 100% copy) after turning on SPPD.

4) When the OC cover is opened during document transport (during SPF motor rotation) (The SPF motor is stopped during document transport, but the OC cover open error occurs instead of the SPF JAM.)

AL-2040CS OPERATIONAL DESCRIPTIONS 7 - 8

D. SPF open/close detection (book document

detection)

SPF open/close detection (book document) detection is performed by detecting the interval between the reference lines on the white Mylar attached to the paper exit guide (document scanning section) by the scanner (CCD) and detecting the varied quantity.

Reference line Reference line

(CCD)

(White Mylar)

B A

(Floating)

A - B = Varied quantity of pixels

(pixel)

[8]

DISASSEMBLY AND ASSEMBLY

Before disassembly, be sure to disconnect the power cord for safety.

1. Do not disconnect or connect the connector and the harness while the machine is powered. Especially be careful not to disconnect or connect the harness between the MCU PWB and the LSU (MCU PWB: CN42) during the machine is powered. (If it is disconnected or connected during the machine is powered, the IC inside the LSU will be destroyed.)

2. To disconnect the harness after turning on the power, be sure to turn off the power and wait for at least 10 sec before disconnection. (Note that a voltage still remains immediately after turning off the power.)

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

9. SPF section

10. 2nd cassette section

1. High voltage section

2) Push up the lock pawls (2 positions) of the side cover, and remove the transfer charger.

Lock pawl rear

Transfer charger

A. List

No. Part name Ref.

1 Transfer charger unit 2 Charger wire

B. Disassembly procedure

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

Lock pawl front

C. Assembly procedure

For assembly, reverse the disassembly procedure.

D. Charger wire cleaning

1) Remove the charger cleaner from the manual paper feed unit.

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 1

2) Set the charger cleaner to the transfer unit, and move it reciprocally a few times in the direction of the arrow shown in the figure below.

2. Operation panel section

A. List

No. Part name Ref.

1 Operation panel unit 2 Operation PWB

B. Disassembly procedure

1) Open the side door, and Open the front cover.

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. Refer to

Fig.1

• 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.

2) Remove the screws (4 pcs.), the harness, and the operation panel unit.

Charger wire

Protrusion

Fig.1

1mm

1.5mm

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 2

3) Remove four screws, and remove the operation cabinet.

4) Remove four screws, and remove the operation PWB.

2) Remove two screws, and remove the earth wire.

3) Disconnect the connector.

4) Remove the SPF unit.

C. Assembly procedure

For assembly, reverse the disassembly procedure

3. Optical section

A. List

NO. Part name Ref.

1 Copy lamp unit 2Copy lamp 3 Lens unit

B. Disassembly procedure

1) Remove four screws, and remove the rear cabinet and the rear cabinet cover.

5) Remove five screws. Remove the operation unit, and disconnect the connector.

6) Remove the right cabinet.

7) Remove the left cabinet.

8) Remove the screw, and remove the rear cover.

9) Remove the table glass.

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 3

10) Move the carriage to the position indicated on the figure.

11) Loosen the screw which is fixing the tension plate.

12) Move the tension plate in the arrow direction to release the tension, and remove the belt.

13) Remove the screw, and remove the rod stopper.

14) Remove the rod.

C. Assembly procedure

CCD core

1) Pass the core through the CCD-MCU harness.

2) Insert the CCD-MCU harness into the CCD PWB connector of the carriage unit.

3) Move the core which was passed through the CCD-MCU harness near the CCD PWB connector as shown in the figure below, and fix it with a filament tape (19mm wide, 40mm long). For the attachment reference, refer to the figure below. Clean and remove oil from the attachment section.

4) Attach the CCD-MCU harness to the duplex tape on the back of the carriage unit.

5) Attach the PWB holder to the position specified in the figure below.

6) Pass the core through the FFC and the PWB holder, and fix the core.

Note: Attach the FFC to the base plate securely with duplex tape to prevent against coming loose.

15) Lift the rear side of the carriage, remove the belt and the connector, and remove the carriage.

Note: Attach the FFC to fit with the marking line.

Marking line

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 4

4. Fusing section

A. List

No. Part name Ref.

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

B. Disassembly procedure

1) Remove the connectors (3 pcs.) of the rear cabinet.

2) Open the side cover, remove two screws, and remove the fusing unit.

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

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 5

7) Remove the plate spring on the right and remove the heater lamp.

10) Remove the spring, and remove the lower separation pawls (4 pcs.).

Heater lamp

8) Remove the spring, and remove the upper separation pawls (3 pcs.).

11) Remove the pressure release levers on the right and the left sides.

12) Remove the pressure roller, the pressure bearing, and the spring.

Note: Apply grease to the sections specified with an asterisk (*).

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

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 6

Pressure roller

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

5) Remove screws, remove the fusing cover, and open the heat roller section.

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

C. Assembly procedure

For assembly, reverse the disassembly procedure.

5. Tray paper feed/transport section

A. List

No. Part name Ref.

1 PPD1 sensor PWB 2 LSU unit 3 Intermediate frame unit 4 Paper feed roller

3) 2

8) Remove two screws and remove the thermo unit. Note: The set temperature of the thermostat differs from that of the

current model.

Temperature Current model 210°C AL-2030/2040CS 230°C

B. Disassembly procedure

1) Remove two screws, and remove the hinge guide R.

2) Disconnect the connector. (2 positions)

3) Remove five screws, and remove the scanner unit.

4) Remove the fan duct.

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 7

5) Remove each connector and four screws, and remove the MCU PWB.

7) Remove two screws and remove the toner motor.

6) Remove the PWB insulation mylar and remove the paper transport detection sensor (PPD2).

8) Remove two springs and open the intermediate frame unit.

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 8

9) Remove the pulleys on the both sides and remove the paper exit roller.

11) Release the belt pulley lock and remove the belt pulley bearing.

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

12) Remove the paper exit roller.

13) Remove the harness guide.

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 9

14) Remove five screws and remove the main drive plate and the belt.

16) Remove four screws, and remove the paper guide unit.

CAUTION:Attach the gears securely

15) Remove the parts as shown below, and remove the pressure release solenoid and the paper feed solenoid.

17) Remove four screws, and remove the LSU unit.

[Note for assembling the LSU]

When installing the LSU, turn the LSU clockwise and fix with screws in order to provide an attachment backlash in the

proper direction. Observe the following sequence of fixing screws.

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 10

18) Remove each pawl, and remove the paper exit tray.

21) Remove the screw and the E-ring, and remove the PS semicircular earth plate and the PS roller unit.

22) Remove the E-ring and remove the spring clutch from the PS roller unit.

PS roller unit

19) Remove two screws and remove the fusing connector.

20) Remove five screws and the connector, and lift the intermediate frame unit to remove.

PS semi-circuler

PS semi-circular earth plate

earth plate

23) Remove three screws and remove the TC front paper guide.

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 11

24) Remove the screw and the connector, and remove the PPD1 sensor PWB.

25) Remove two E-rings and remove the paper feed roller.

26) Remove three E-rings and remove the clutch unit.

6. Manual paper feed section

A. List

No. Part name Ref.

1 Manual transport roller 2 Cassette detection switch 3 PPD1 sensor PWB 4 Side door detection unit

B. Disassembly procedure

Multi unit

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

Paper feed roller

Back

Clutch unit

Front

C. Assembly procedure

For assembly, reverse the disassembly procedure.

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 12

2) Remove the screw and remove the side door detection unit.

Back Wire treatment

3) Remove three screws and remove the multi paper feed upper frame.

4) Remove two screws and remove the multi feed bracket unit from the multi paper feed upper frame.

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

roller B9.

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 13

6) Remove the pick-up roller.

7) Cut the binding band and remove the multi paper feed solenoid.

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

Multi paper feed solenoid

C. Assembly procedure

For assembly, reverse the disassembly procedure.

7. Rear frame section

A. List

No. Part name Ref.

1 Scanner motor 2 Main motor 3 Exhaust fan motor 4NIC PWB 5 Main PWB

B. Disassembly procedure

1) Remove four screws, and remove the rear cabinet and the rear cabinet cover.

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 14

2) Disconnect the connector.

3) Remove two screws, and remove the scanner motor.

6) Disconnect the connector.

7) Remove the two screws, and remove the NIC PWB.

4) Remove two screws and one harness, and remove the main motor.

8) Disconnect the connector.

9) Remove the three screws, and remove the NIC PWB unit.

5) Remove two screws and one connector, and remove the exhaust fan motor.

10) Disconnect the connectors.

11) Remove the five screws, and remove the MCU PWB.

C. Assembly procedure

For assembly, reverse the disassembly procedure.

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 15

8 Power section

A. List

No. Part name Ref.

1Power PWB

B. Disassembly procedure

1) Disconnect each connector.

2) Remove the screw, and remove the earth line.

3) Remove two screws, and remove the power PWB unit.

A. SPF motor

1) Remove the screw.

2) Disengage the pawl (3 positions).

3) Remove the rear cabinet.

C. Assembly procedure

For assembly, reverse the disassembly procedure.

9. SPF section

No. Part name Ref.

A SPF motor

B Pick-up roller, paper feed roller C Paper exit roller D Set sensor, scan front sensor

E Transport roller

(1) Rear cabinet disassembly

1) Remove four screws.

2) Remove the rear cabinet.

(2) Remove the SPF.

1) Remove two screws, and remove the earth wire.

2) Disconnect the connector.

3) Remove the SPF unit.

1) Remove the screw, and remove the harness.

2) Remove three screws.

3) Disengage the pawl (4 positions).

4) Remove the transport unit.

1) Remove two screws, and remove the earth wire.

2) Remove the SPF motor unit.

3) Disconnect the connector.

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 16

1) Remove two screws.

2) Remove the SPF motor.

1) Remove the shaft.

2) Remove the paper feed roller.

3) Remove the bearing and the spring.

B. Pick-up roller, paper feed roller

1) Remove two gears.

1) Remove the pick-up roller.

2) Remove the gear.

1) Open the upper door.

2) Remove two E-rings, and remove the spring, the arm, and the bearing.

3) Remove the pick-up roller unit.

C. Paper exit roller

1) Remove four gears.

2) Remove two screws.

3) Remove the frame.

1) Remove the E-ring.

2) Remove the bearing.

3) Remove the paper guide unit.

4) Remove the paper exit roller.

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 17

D. Set sensor, scan front sensor

1) Remove the set sensor.

2) Remove the scan front sensor.

3) Disconnect the connectors.

∗ When assembling, attach the blue harness to the marking B

side of the sensor, and attach the orange harness to the opposite side sensor.

10. 2nd cassette section

No. Part name Ref.

A Paper sensor B Cassette detection SW C Paper feed solenoid D Transport roller E Paper feed clutch

F 2nd paper feed roller

Paper feed unit removal

1) Remove the screw.

2) Remove the rear cover. ∗ When installing, engage the pawl and install the unit.

E. Transport roller

1) Remove the actuator.

2) Remove the transport roller.

3) Remove the gear and the bearing.

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 18

1) Open the right cabinet.

2) Remove three screws.

3) Remove one connector from MCU.

4) While tilting down the 2nd connection arm A, pull and remove the paper feed unit toward you.

B. Cassette detection switch

1) Remove the pawl.

2) Remove the cassette detection switch.

3) Remove the harness.

∗ When installing, securely insert two bosses C on the machine

side and two bosses D on the paper feed unit side. Be sure to secure the ground wire B.

∗ Insert the 2nd page feed.

A. Paper sensor

1) Remove the pawl.

2) Remove the paper sensor.

3) Remove the harness.

C. Paper feed solenoid

1) Remove the screw.

2) Remove the connector.

3) Remove the paper feed solenoid.

D. Transport roller

1) Remove two E-rings.

2) Remove the transport roller.

∗ Install so that the earth spring A is brought into contact over

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 19

bearing B.

E. Paper feed clutch

1) Remove the E-ring.

2) Remove the paper feed clutch.

3) Remove the parts.

∗ When installing, fit the cut surface A.

F. 2nd paper feed roller

1) Remove the E-ring and the parts.

2) Remove the 2nd paper feed roller.

∗ When installing, hang the 2nd connection arm on the 2nd con-

nection arm Spring B. Be sure to install so that the earth spring C is in contact under the bearing D.

AL-2040CS DISASSEMBLY AND ASSEMBLY 8 - 20

[9] ADJUSTMENTS

1. Optical section

A. 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.

(1) 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 carriage (scanner) scanning speed.

(2) Main scanning direction magnification ratio

adjustment

a. Cases when the adjustment is required

1) When the main PWB is replaced.

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

3) When "U2" trouble occurs.

4) When repairing or replacing the optical section.

b. Necessary tools

• Screwdriver (+)

•Scale

c. Adjustment procedure

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

2) Set the copy magnification ratio to 100%.

3) Make a copy on A4 or 81/2" x 11" paper.

4) Measure the length of the copied scale image.

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

Copy image dimensions

Original dimension

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

Paper feed direction

mm 1/2mm

10 20

Reference

X 100 (%)

110

JAPAN

120 130

100 110 120 130

100

Comparison point

140

Original (Scale)

HARDENED STAINLESS

150

Shizuoka

HARDENED STAINLESS

150

Shizuoka

Copy

110

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 START 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 Default

Main scanning direction

TEXT lamp ON 50

magnification ratio adjustment Sub scanning direction

PHOTO lamp ON 50

magnification ratio adjustment

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

9) Change the set value and repeat the adjustment until the ratio is within the specified range. When the set value is changed by 1, the magnification ratio is changed by 0.1%.

(3) Sub scanning direction copy magnification ratio

a. Cases when the adjustment is required

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

2) When the main PWB is replaced.

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

4) When "U2" trouble occurs.

b. Necessary tools

•Scale

AL-2040CS ADJUSTMENTS 9 - 1

c. Adjustment procedure

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

2) Set the copy magnification ratio to 100%.

3) Make a copy on A4 or 81/2" x 11" paper.

4) Measure the length of the copied scale image.

5) Calculate the sub scanning direction copy magnification ratio using the formula below.

Copy image dimensions

Original dimension

X 100 (%)

110

Original (Scale)

HARDDENCD

mm 1/2mm

Reference

10 20

100

Comparison point

JAPAN

110 120 130

JAPAN

110 120

130

STAINLESS

140

150

Shizuoka

HARDDENCD STAINLESS

140

150

Shizuoka

Copy

Paper feed direction

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 lamp ON)

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

B. 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, 50-06, 5010, 50-18 and SIM 50-19 are used.

No. Adjustment item Simulation

1 Print start position (Main cassette) 50 - 01 2 Print start position (2nd cassette) 50 - 01 3 Print start position (Manual feed) 50 - 01 4 Image lead edge void amount 50 - 01 5 Image scan start position 50 - 01 6 Image rear edge void amount 50 - 01 7 SPF image scan start position 50 - 06 8 SPF rear edge void amount 50 - 06 9 Center offset 50 - 10

10 Memory reverse position adjustment in

duplex copy 11 Duplex copy rear edge void adjustment 50 - 19 12 Duplex back print start position 50 - 19

To select the adjustment mode with SIM 50-01, use the copy mode select key.

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

Adjustment mode Lamp ON

Print start position (Main cassette

AE, main cassette lamp

paper feed) Print start position (2nd cassette

AE, 2nd cassette lamp

paper feed) Print start position (Manual paper

AE, manual feed lamp

feed) Image lead edge void quantity TEXT lamp Image scan start position PHOTO lamp Image rear edge void quantity AE, TEXT, PHOTO lamp

: Supported for the installing model and skipped for non-install-

ing mode.

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

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 Lamp ON

Print center offset (Main cassette

AE, main cassette lamp

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

feed)

AE, manual paper feed lamp

Second side center offset TEXT lamp

: Supported for the installing model and skipped for non-install-

ing mode.

50 - 18

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%.

AL-2040CS ADJUSTMENTS 9 - 2

(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" x 14" paper.

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%.

4) Measure the image loss amount (R mm) of the scale image. Set C = 10 X 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 X 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

(2) Image rear edge void amount adjustment

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

Scale image

Paper rear edge

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.

Note: The rear edge void cannot be checked with the first sheet

after entering the simulation mode, the first sheet after turning off/on the power, or the first sheet after inserting the cassette. Use the second or later sheet to check the rear edge void.

(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" x 11" paper in the paper transport direction.

Document guide

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.

AL-2040CS ADJUSTMENTS 9 - 3

Center

Copy paper (A4 or 8 1/2″ × 11″)

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

(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 DENSITY

12345678910W

No. UKOG-

0089CSZZ DENSITY

0.1 0.2 0.3 0.5 1.9 0

No. KODAK

GRAY

123419A

SCALE

D. 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 Brightness 5 steps. Adjustment of only the

Photo Mode Brightness 5 steps. Adjustment of only the

Manual T/S mode Brightness 5 steps. Adjustment of only the

T/S Auto mode Brightness 1 step only

center brightness is made.

2. Copy density adjustment

A. 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.

B. 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 devel-

oping bias voltage are in the specified range.

C. Necessary tool for copy density adjustment

• One of the following test charts:

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

• B4 (14" x 8 1/2") white paper

• The user program AE setting should be "3."

1 10

23456789

E. Copy density adjustment procedure

Use SIM 46-1 to set the copy density for each copy mode. For selection of modes, use the copy mode select key.

(1) 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 A4 (14" x 8 1/2") white paper on the test chart and close the document cover.

White paper

Test chart

AL-2040CS ADJUSTMENTS 9 - 4

(2) 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) (2)

Mode select key/display lamp

(1)

Exposure level select key/

(2)

display lamp

Adjustment

mode Auto mode Auto lamp ON "3" is slightly copied. Manual mode Manual lamp ON "3" is slightly copied. Photo mode Photo lamp ON "3" is slightly copied. Manual T/S

mode Auto T/S mode Auto lamp/Photo lamp ON "3" is slightly copied.

3) Make a copy. Check the adjustment level (shown in the above table) of the exposure test chart (Sharp Gray Scale).

Non toner save mode

Not copied.

Toner save mode

Not copied.

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

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

∗ The value can be set in the range of 1 - 99.

Exposure mode

display lamp

Sharp gray chart

adjustment level

Manual lamp/Photo lamp ON"3" is slightly copied.

Sharp Gray Scale adjustment level

1 10

23456789

Slightly copied.

1 10

23456789

Slightly copied.

quantity display.

tity display.

3. High voltage adjustment

A. 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 (power frame).

3) Execute SIM 8-2. (The main charger output is supplied for 30

sec in the grid voltage HIGH output mode.)

4) Adjust the control volume (VRG1) so that the output voltage is

580 ±12V.

VRG1

B. DV bias check

Note: • A digital multi meter with internal resistance of 1GΩ must

be use for correct check.

• The adjustment volume is locked, and no adjustment can be made.

Procedures

1) Set the digital multi meter range to DC500V.

2) Set the positive side of the test rod to the connector CN-10-1 (DV BIAS) and set the negative side to the frame ground (power frame).

3) Execute SIM 8-1 to output the developing bias for 30sec, and check that the output is –400 ± 8V.

AL-2040CS ADJUSTMENTS 9 - 5

VRDV

4. Duplex adjustment

A. Adjusting the paper reverse position in

memory for duplex copying

This step adjusts the front surface printing (odd-number pages of a document set) in the S-D mode copying.

That is, it covers the adjustment of the second surface printing mode (image loss at the front edge of an image) in which image data is once stored in memory.

The image data is read, starting from its front end in the document delivery direction (Reference direction of document setting in the OC mode)and stored in memory.

This stored image data is printed starting at the printing start position, in the order of last-stored data to the first-stored data.

In other words, the front edge image loss of the image can be adjusted by changing the document read end position.

(Adjustment procedure)

1) Preparing test chart (Draw a scale at the rear end of one side of a sheet of A4 white paper or letter paper)

510

2) Set the test chart so that the scale is positioned as shown below, in the S-D mode.

2nd printing surface where scale is printed (lower side)

B. Adjusting trailing edge void in duplex copy

mode

This is the adjustment of the first surface printing mode (rear end void) in duplex copying.

In a duplex copying operation, the paper is delivered starting from the rear end of the first printing surface. It is therefore necessary to make a void area at the rear end on the first printing surface to prevent paper jam at the fusing part.

There are two adjustment modes:

1) Paper trailing edge void quantity 50-19 (TEXT) This adjustment is made when the cassette paper size is recognized. The trailing edge void quantity can be adjusted by changing the trailing edge image laser OFF timing.

Print start position (Duplex back surface) (SPF) 50-19 (PHOTO)

2) The size (length) of a document read from the SPF is detected, the image at the trailing edge of the first printing surface is cut to make a void area. (The adjustment of void quantity at the time when the cassette paper size is not recognized.)

Scale (S-D mode)

3) Execute SIM 50-18 to make a copy and check the front edge image loss at the area where the scale is printed. Adjust the setting so that the front edge image loss is less than

4.0 mm in the SPF mode. An increase of 1 in setting represents an increase of 0.1 mm in image loss.

Front edge of paper

The front edge of the scale on test chart

less than 4 mm

510

Void area

The paper void quantity should be first adjusted before the image cut trailing edge void quantity (SPF) is adjusted.

(Adjustment procedure)

(1) Paper trailing edge void quantity

1) Preparing test chart (Draw a scale at the rear end of one side of a sheet of A/4 white paper or letter paper)

2) Set the test chart on the document glass as shown below.

Document guide

The trailing edge has a scale

Table glass

3) Using the user simulation [18], set the paper size of the first cassette.

• Letter paper: 4

• A4 paper: 3

AL-2040CS ADJUSTMENTS 9 - 6

4) Execute SIM 50-19 to turn on the TEXT lamp and make the printing mode in OC-D mode. Make a copy of the test chart to check the void area of the scale on the image.

Void position to be check

Paper

The trailing edge void on the first printing surface is shown above.

Adjust the setting so that the void area is 4 - 5 mm. An increase in 1 of setting represents 0.1 mm in void area.

(2) Print start position (Duplex back surface)

1) Set the test chart so that the scale is positioned as shown below.

The density select key is used to select the mode.

Mode Default LED

SPF scan position auto adjustment

SPF scan position manual adjustment

Operation

The operation is similar to SIM 46-01. (In MANUAL)

50 AE mode lamp

50 TEXT mode lamp

Scale (S-D mode)

2) Execute SIM 50-19 to turn on the PHOTO lamp (on the operation panel) and make the printing mode in the S-D mode.

3) Remove and reinsert the cassette.

Note: Make sure to carry out this step before making a copy dur-

ing this adjustment.

4) Make a copy and check the void area of the scale on the image. Adjust the setting so that the void area is 2 - 4 mm. An increase of 1 in setting represents an increase of 0.1 mm in void area. Void position to be checked

5. SPF scan position automatic

adjustment

Fold two sheets of A4 paper (white chart) into two, and place them so that they cover the SPF scan glass and the OC glass together, and close the OC cover.

When SIM 53-08 is executed, the current adjustment value is displayed as the initial display.

∗ Default is 50. Adjustment range is 1 – 99. Adjustment unit 1 =

about 0.127mm

In the case of AUTO, when START key is pressed, the mirror unit scans from the home position to the SPF scan position with the current adjustment value displayed. Then the SPF glass cover edge position is determined from the difference in the CCD output levels of the SPF glass cover edge and the OC side document glass. If the adjustment is completed normally, the adjusted value is displayed on the 7seg/LCD. If it is terminated abnormally, the following lamp is turned ON. "JAM lamp": When the operation is canceled by pressing C key during execution, the mirror is returned and "- -" is displayed.

6cm or more is required.

6. SPF mode sub scanning direction magnification ratio adjustment

Note: Before performing this adjustment, be sure to check that the

OC mode adjustment in copying has been completed.

1) Put a scale on the original table as shown below, and make a

normal copy (100%) on the front and the back surfaces to make a test chart.

Note: Since the printed copy is used as a test chart, put the scale

in paralled with the edge lines.

2) Set the test chart on the SPF and make a copy in the normal

ratio (100%).

3) Compare the scale image and the actual image.

If necessary, perform the following adjustment procedures.

4) Execute SIM 48-05.

5) The current sub scanning direction magnification ratio correc-

tion value is displayed in two digits on the display section.

6) Enter the set value and press the START key.

Mode Display item Default LED

Sub scan magnification ratio adjustment on the surface of SPF document

∗ When there is no document in SPF, copy is inhibited.

SIDE1 50 AE mode

lamp

AL-2040CS ADJUSTMENTS 9 - 7

Adjustment mode

Sub scanning direction magnification ratio (SPF mode)

Spec

value

At normal: ±1.0%

SIM Set value

48-5 Add 1:

0.1% increase Reduce 1:

0.1% decrease

Setting

range 1 – 99

7. Automatic black level correction

a. Cases when the adjustment is required

1) When the main PWB is replaced.

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

3) When "U2" trouble occurs.

4) When repairing or replacing the optical section.

b. Adjustment procedure

Used to acquire the black level target value used for the black level adjustment of white balance.

When SIM 63-02 is executed, the current correction value is displayed in 3 digits of 12bit hexadecimal number.

Place the gray gradation chart (UKOG-0162FCZZ) used as the correction document so that the density 10 (black side) comes on the left side and that the chart is upside down at the center of the plate left center.

Chart back surface

When START key is pressed, the mirror base unit scans the chart and calculates the correction value.

After completion of correction, the corrected value is displayed on the display section.

∗ Default: 0 ∗ If the value is set to the default, operation is made with 0x60.

AL-2040CS ADJUSTMENTS 9 - 8

[10] SIMULATION, TROUBLE CODES

1. Entering the simulation mode

To enter the serviceman simulation mode, press the keys as follows: Clear → Density select → Clear→ Density select To cancel the simulation mode, press the clear key. Flow chart of entering the simulation mode

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

Perform 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 ready 7 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 1sec

Press the exposure mode selector key.

Within 1sec

Press the clear key.

Within 1sec

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

AL-2040CS SIMULATION, TROUBLE CODES 10 - 1

2. List of simulations

Sim

No.

Kind of

main code

01 Optical system 01 Mirror scan operation

02 SPF Individual

load operation

05 Lamp ON

check

06 Machine

individual load operation

07 Aging 01 Warm-up display and aging with jam

08 High voltage

output check

09 01 Duplex motor normal rotation

10 Toner motor

operation check 14 Trouble reset 00 Cancel of troubles other than U2 16 U2 trouble

reset 22 Counter display 04 JAM total counter display

24 Counter clear 01 JAM total counter clear

25 Main motor ON 01 Main motor operation check (Cooling

26 Various setup 02 SPF setup

Sub

code

02 Mirror home position sensor (MHPS)

status display 06 Aging of mirror scanning 01 Single Paper Feeder (SPF) aging

operation 02 SPF sensor status display 03 Motor ON 06 Resist clutch ON (SPF) 08 SPF paper feed solenoid operation

check 01 Operation panel display check 02 Fusing lamp, cooling fan operation

check 03 Copy lamp ON 01 Paper feed solenoid ON 02 Resist solenoid ON

06 Intermittent aging 08 Shift to copy with the warm-up display. 01 Developing bias 02 Main charger (Grid high) 03 Grid voltage (Low) 06 Transfer charger

operation check <Duplex model only> 02 Duplex motor reverse operation check

<Duplex model only> 04 Duplex motor rotation speed

adjustment <Duplex model only> 00 Toner motor aging

00 Cancel of U2 trouble

05 Total counter display 08 SPF counter display 12 Drum counter display 14 ROM version display 16 Duplex counter display

<Duplex model only> 17 Copy counter display 18 Printer counter display 19 Scanner mode counter display

(AL-2040CS only) 21 Scanner counter display 22 SPF JAM counter display

04 SPF counter clear 05 Duplex counter clear

<Duplex model only> 07 Drum counter clear 08 Copy counter clear 09 Printer counter clear 13 Scanner counter clear 14 SPF JAM total counter clear 15 Scanner mode counter clear

(AL-2040CS only)

fan motor rotation check) 10 Polygon motor ON

03 Second cassette setup 04 Machine duplex setup 06 Destination setup 07 Machine conditions check 20 Rear edge void setup

Operation

Sim

No.

Kind of

main code

26 Various setup 30 CE mark support control ON/OFF

30 Sensor

operation check (Standard provision)

41 06 OC cover float detection level

43 Fusing

temperature setup

46 Exposure

adjustment

48 Magnification

ratio correction

49 01 Flash ROM program writing mode 50 Lead edge

adjustment

51 Timing

adjustment

53 08 SPF scan position automatic

61 Laser system

operation

63 Shading 01 Shading check

64 Self print 01 Self print 67 50 USB receive speed adjustment

Sub

code

38 Cancel of stop at drum life over 39 Memory capacity check 40 Polygon motor OFF time setup

(Time required for turning OFF after

completion of printing) 42 Transfer ON timing control setup 43 Side void setup 62 Energy-save mode copy lamp setup 01 Paper sensor status display

adjustment 07 OC cover float detection margin

setting 01 Fusing temperature setting (Normal

copy) 04 Fusing temperature setting in multi

copy 05 Fusing temperature setup in duplex

copy 09 Fusing control setting for postcard-size

paper 11 Fusing temperature setting for

postcard-size paper 14 Fusing start temperature setting 15 Postcard size paper fusing control

cycle sync setting 01 Copy density adjustment (300dpi) 02 Copy density adjustment (600dpi) 18 Image contrast adjustment (300dpi) 19 Exposure mode setup 20 SPF exposure correction 29 Image contrast adjustment (600dpi) 30 AE limit adjustment 31 Image sharpness adjustment 32 Copier color reproduction setup 01 Front/rear (main scanning) direction

and scan (sub scanning) direction

magnification ratio adjustment 05 The current SPF mode sub scan

direction magnification ratio is

displayed on the LCD/7seg.

01 Lead edge image position 06 Copy lead edge position adjustment

(SPF) 10 Center offset adjustment 12 Document off-center adjustment 18 Memory reverse position adjustment in

duplex copy 19 Duplex copy rear edge void

adjustment 02 Resist quantity adjustment

adjustment 03 Polygon motor check (HSYNC output

check)

02 Black level automatic correction 12 Light quantity stabilization wait time

setting 13 Light quantity stabilization band

setting

(USB1.1)

Operation

AL-2040CS SIMULATION, TROUBLE CODES 10 - 2

3. Contents of simulations

Input method: Clear key → Exposure Select key → Clear key → Exposure Select key

Main

Sub

code

01 01 Mirror scan operation

(Operation/Procedure)

1. When this simulation is executed, the mirror home position is detected. Sensor name Display lamp

Mirror home position sensor OPC drum cartridge replacement lamp

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.

02 Mirror home position sensor (MHPS) status display

The mirror home position sensor is monitored, and the sensor status is displayed as follows: (The lamp is lighted while the sensor is ON.) [Photoconductor drum cartridge replacement lamp]

06 Aging of mirror scanning

When the PRINT switch is pressed, the mirror base performs full scan at the speed of the set magnification ratio. After 3 sec, the mirror case performs full scan again. These procedures are repeated until the clear key is pressed. (When the PRINT switch is pressed once, the ready lamp keeps OFF.) The status of the mirror home position sensor is displayed with the photoconductor cartridge lamp. (The lamp is ON when the mirror is at the home position.) During aging, the copy lamp keeps ON.

02 01 Single Paper Feeder (SPF) aging operation

05 01 Operation panel display check

When START key is pressed, the set magnification ratio is obtained. For the SPF, the single surface document transport operation is performed. For the R-SPF, the duplex document transport operation is performed. Since, however, there is no required operating condition, the operation is not stopped even when a JAM occurs. The magnification ratio change and the operation status display are Similar to SIM 1-01.

02 SPF sensor status display

ON/OFF of the sensors in the SPF can be checked with the following lamps.

Display Sensor Developer cartridge replacement lamp Document set detection (SPID) Jam lamp SPF document transport detection (SPPD)

03 Motor ON

(Operation/Procedure) When the start key is pressed, the SPF motor rotates for 10 sec at the speed corresponding to the currently set magnification ratio.

06 Resist clutch ON (SPF)

(Operation/Procedure) When the start key is pressed, the RSPF resist clutch (SRRC) repeats ON (500 ms) and OFF (500 ms) 20 times.

08 SPF paper feed solenoid operation check

The SPF paper feed solenoid (SPUS) is turned ON for 500msec and OFF for 500msec. This procedure is repeated 20 times.

• When the PRINT switch is pressed, all LEDs (including 7-segment LEDs) on the operation panel are lighted. (LED check mode)

• When 1Up key is pressed, the LEDs on the operation panel are lighted individually from the top left to the bottom right in sequence. After completion of all individual lighting, all LEDs are lighted simultaneously. (The 7-segment LED lights the three-digit sections at the same time.) Individual lighting frequency ON: 300ms, OFF: 20ms

• When the CLEAR key is pressed, this simulation is terminated.

• When the PRINT switch is pressed in the LED check mode, the machine enters the Key input check mode.

“Key input check mode” When the machine enters the Key input check mode, the value display section indicates “– – –.” Every time any key on the operation panel is pressed, the entered value is added and displayed on the value display section. However, the keys that were pressed once are not counted again.

• When the PRINT switch is pressed, the entered value is added and displayed for 3 sec and all the LEDs are lighted. (LED lighting check mode)

(Note for Key input check mode)

• Press the PRINT switch at the end. (If it is pressed in the middle of the process, the entered value up to that moment is displayed for 3 sec and the machine enters the LED lighting check mode. (ALL the LEDs are lighted.))

• Multiple key inputs are ignored.

02 Fusing lamp, cooling fan operation check

When the PRINT switch is pressed, the fusing lamp repeats operations of 500ms-ON and 500ms-OFF 5 times. During that time, the cooling fan motor rotates.

Content

AL-2040CS SIMULATION, TROUBLE CODES 10 - 3

Main code

Sub

code

Content

05 03 Copy lamp ON

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

06 01 Paper feed solenoid ON

(Operation/Procedure) When the START key is pressed, the paper feed solenoid selected by the tray select key repeats ON (500ms) and OFF (500ms) 20 times.

02 Resist solenoid ON

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

07 01 Warm-up 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.

This simulation is canceled by turning off the power or executing any simulation which performs hardware reset.

06 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.

This simulation is canceled by turning off the power or executing any simulation which performs hardware reset.

08 Shift to copy with the warm-up display.

When the simulation code is entered, warming-up is started. The warming-up time is counted from 0 in the increment of 1 sec. The operation during count-up process is as stated below. When C key is pressed, the operation is terminated. (The 7-seg display indicates the sub code.) Warming-up operation is continued. After completion of warming-up, counting is terminated. (This is similar to SIM 07-01 without the aging function.

08 01 Developing bias

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

02 Main charger (Grid high)

(Operation/Procedure) When the START key is pressed, the main charger output is supplied for 30 sec in the grid voltage HIGH mode.

03 Grid voltage (Low)

(Operation/Procedure) When the START key is pressed, the main charger output is supplied for 30 sec in the grid voltage LOW mode.

06 Transfer charger

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

09 01 Duplex motor normal rotation operation check <Duplex model only>

The duplex motor is rotated in the normal direction (paper exit direction) for 30 sec. After completion of the process, the display returns to the sub code input standby state.

02 Duplex motor reverse operation check <Duplex model only>

The duplex motor is driven in the reverse direction for 30 sec. After completion of the process, the display returns to the sub code input standby state.

04 Duplex motor rotation speed adjustment <Duplex model only>

When this simulation is executed, the current set value is displayed. Enter the adjustment value with UP/UP key, and press START key to save the entered value. The display returns to the sub code input standby mode. When the set value is increased, the speed is increased, When the set value is decreased, the speed is decreased. Setup range: 1 – 13 Default: 6

10 00 Toner motor aging

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

14 00 Cancel of troubles other than U2

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

16 00 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.

AL-2040CS SIMULATION, TROUBLE CODES 10 - 4

Main

Sub

code

22 04 JAM total counter display

The display method is the same as the total count value display. <Display example: 12345>

012 → Blank → 345 → Blank → 012

0.7s 0.3s 0.7s 1.0s 0.7s

05 Total counter display

The total count value is displayed in 3 digits X 2 times repeatedly.

08 SPF counter display