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Sharp AL-2040CS User Manual

Sharp AL-2040CS
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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
for after sales service only.
The contents are subject to change without notice.
SERVICE MANUAL
CONTENTS
SHARP CORPORATION
CODE: 00ZAL2040CS1E
DIGITAL MULTIFUNCTIONAL
SYSTEM
AL-2030
MODEL AL-2040CS
(AL-2040CS)
[ 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
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Sharp AL-2040CS Specifications

General IconGeneral
Zoom capabilityYes
Copy speed (black, normal quality, A4)20 cpm
Maximum print sizeA4 (210 x 297 mm)
Standard input capacity250 sheets
Auto document feeder (ADF) input capacity50 sheets
Print technologyLaser
Time to first page (black, normal)8 s
Print speed (black, normal quality, A4/US Letter)16 ppm
Standard interfacesUSB & Ethernet/LAN
Mac compatibilityNo
Minimum system requirementsUSB
Compatible operating systemsWindows 98/ME/2000/XP/vista
TypeDigital copier
Dimensions (WxDxH)520.7 x 450.8 x 450.8 mm
Power requirements120VAC +/- 10%; 60HZ +/- 2%
Bundled softwareSharpdesk 2.7 desktop management software with OCR

Summary

Major Functions

Specifications Overview

Basic Specifications

Details the fundamental technical specifications of the copier.

Operation Specifications

Outlines the operational parameters and capabilities of the copier.

Copy Performance

Describes the performance metrics and capabilities related to copying.

GDI Printer Specifications

Information specific to the GDI printer functionality and requirements.

Scan Function Specifications

Details the functionality and specifications of the scanner unit.

SPF Specifications

Information regarding the Single Path Feeder functionality and its specifications.

Consumable Parts Overview

Supply System Table

Lists and describes the consumable parts for the copier.

Environmental Conditions for Operation

Specifies the recommended environmental conditions for optimal operation.

Production Control Number Identification

Explains how to identify production control numbers (lot numbers) on parts.

External Views and Internal Structures

External Appearance Overview

Shows the exterior view of the copier and its main external parts.

Internal Component Identification

Identifies and labels the key internal components of the copier.

Operation Panel Overview

Explains the function of each key, indicator, and display on the operation panel.

Using the SCAN Key for Scanning

Explains how to use the SCAN key to initiate scanning operations and select applications.

Motors and Solenoids Identification

Lists and describes the motors and solenoids used in the copier's mechanisms.

Sensors and Switches Identification

Lists and describes the sensors and switches utilized in the copier's operation.

Printed Wiring Board (PWB) Units

Identifies the various Printed Wiring Board (PWB) units within the copier.

Cross-Sectional View of Copier

Provides a detailed cross-sectional diagram of the copier's internal structure.

Unpacking and Installation Guide

Copier Installation Procedures

Step-by-step instructions for installing the copier in its operating location.

Handling Cautions and Precautions

Important safety notes and precautions to follow when handling the copier.

Checking Packed Components and Accessories

Instructions for verifying that all components and accessories are included after unpacking.

Unpacking the Copier Unit

Detailed steps for safely unpacking the copier unit from its packaging.

Removing Packing Materials

Instructions for removing protective packing materials from the copier.

Installing the TD Cartridge

Procedure for installing the TD cartridge into the copier.

Loading Paper into Trays

Instructions on how to load paper correctly into the paper trays.

Powering the Copier On and Off

Steps for connecting power and turning the copier on and off.

Software Installation Guide

Instructions for installing necessary software, including drivers and utilities.

Printer and MFP Drivers Installation

Details for installing printer and MFP drivers for AL-2030 and AL-2040CS.

Scanner and Utility Software Installation

Instructions for installing scanner driver, Sharpdesk, and Button Manager.

Connecting Interface Cables

Guides for connecting the copier to a computer using USB or LAN.

USB Connection Procedure

Step-by-step guide for connecting the machine via USB cable.

Network (LAN) Connection Procedure

Instructions for connecting via LAN for network printing functionality.

Moving the Unit Safely

Procedures and precautions for moving the copier unit.

Copy Process Overview

Functional Diagram of Copy Process

Presents a functional diagram illustrating the copy process cycle.

Outline of Print Process

Describes the general steps involved in the printing process.

Print Process Steps Explained

Details the sequential steps involved in the printing process.

Actual Print Process Details

Provides detailed explanations of each stage in the actual print process.

Actual Print Process Steps Detailed

Provides detailed explanations of each stage in the actual print process.

Optical Discharge and Process Control

Explains optical discharge, Scorotron charging, process control, and developing bias.

Operational Descriptions

Outline of Operation

Describes the basic configuration and operational flow of the copier.

Copy Operation Flow

Describes the sequence of operations for copying, from setting conditions to paper output.

Printer and Scanner Operation

Explains how the unit functions as a printer and a scanner.

Scanner Section Details

Details the scanner unit, including optical and drive systems.

Scanner Unit Components

Details the scanner unit, including optical and drive systems.

Scanner Optical System

Explains the light source, mirrors, lens, CCD, and resolution of the scanner.

Scanner Drive System

Describes the components and mechanism of the scanner's drive system.

Laser Unit Details

Details the basic structure, beam path, and composition of the laser unit.

Laser Unit Structure and Components

Details the basic structure, beam path, and composition of the laser unit.

Fuser Section Details

Provides a general description of the fuser section, including its components and thermal control.

Fuser Section Overview

Provides a general description of the fuser section, including its components and thermal control.

Paper Feed and Transport Operations

Explains the paper feeding and transport mechanisms.

Cassette Paper Feed Operation

Explains the step-by-step process of feeding paper from the cassette.

Manual Multi Paper Feed Operation

Describes the procedure for feeding paper manually using multiple feed options.

New Drum Detection Mechanism

Explains the mechanism for detecting the installation of a new drum.

SPF Section Outline

Provides an overview of the Single Path Feeder (SPF) section.

SPF Document Transport Path and Composition

Details the document transport path and basic composition of the SPF.

SPF Operational Descriptions

Explains the operational aspects and conditions of the SPF.

SPF Jam Generation Conditions

Explains conditions that lead to paper jams in the SPF.

SPF Open/Close Detection (Book Document)

Details how book document detection is performed by the SPF.

Disassembly and Assembly Procedures

High Voltage Section Disassembly

Provides procedures for disassembling and assembling the high voltage section.

Charger Wire Cleaning Procedure

Instructions for cleaning the charger wire.

Charger Wire Replacement Procedure

Steps for replacing the charger wire in the high voltage section.

Operation Panel Section Disassembly

Provides procedures for disassembling and assembling the operation panel.

Optical Section Disassembly

Provides procedures for disassembling and assembling the optical section.

Fusing Section Disassembly

Provides procedures for disassembling and assembling the fusing section.

Tray Paper Feed/Transport Section Disassembly

Provides procedures for disassembling and assembling the tray paper feed/transport section.

Manual Paper Feed Section Disassembly

Provides procedures for disassembling and assembling the manual paper feed section.

Rear Frame Section Disassembly

Provides procedures for disassembling and assembling the rear frame section.

Power Section Disassembly

Provides procedures for disassembling and assembling the power section.

SPF Section Disassembly

Provides procedures for disassembling and assembling the SPF unit and its components.

SPF Rear Cabinet Disassembly

Steps for removing the rear cabinet to access the SPF.

SPF Unit Removal

Procedures for removing the SPF unit itself.

SPF Motor Disassembly

Steps for disassembling the SPF motor.

SPF Pick-up Roller and Paper Feed Roller Disassembly

Steps for disassembling SPF pick-up and paper feed rollers.

SPF Paper Exit Roller Disassembly

Steps for disassembling the SPF paper exit roller.

SPF Set Sensor and Scan Front Sensor Disassembly

Steps for disassembling SPF set sensor and scan front sensor.

SPF Transport Roller Disassembly

Steps for disassembling the SPF transport roller.

2nd Cassette Section Disassembly

Provides procedures for disassembling the 2nd cassette section.

2nd Cassette Paper Feed Unit Removal

Steps for removing the 2nd cassette paper feed unit.

2nd Cassette Component Disassembly

Details disassembly for sensors, rollers, and solenoids in the 2nd cassette.

2nd Cassette Paper Sensor Disassembly

Steps for removing the paper sensor in the 2nd cassette.

2nd Cassette Detection Switch Disassembly

Steps for removing the cassette detection switch.

2nd Cassette Paper Feed Solenoid Disassembly

Steps for removing the paper feed solenoid.

2nd Cassette Transport Roller Disassembly

Steps for removing the transport roller.

2nd Cassette Paper Feed Clutch Disassembly

Steps for removing the paper feed clutch.

2nd Cassette 2nd Paper Feed Roller Disassembly

Steps for removing the 2nd paper feed roller.

Adjustments and Calibration

Optical Section Adjustments

Procedures for adjusting copier magnification and image position.

Magnification Ratio Adjustment Overview

Explains automatic and manual adjustment of copy magnification ratios.

Main Scanning Magnification Ratio Adjustment

Details the procedure for adjusting the magnification ratio in the main scanning direction.

Sub Scanning Magnification Ratio Adjustment

Details the procedure for adjusting the magnification ratio in the sub scanning direction.

Image Position Adjustments

Details various image position adjustments using simulation modes.

Lead Edge Adjustment Procedure

Adjusts the copy image position and lead edge void quantity.

Image Rear Edge Void Adjustment Procedure

Adjusts the image rear edge void amount on the copy paper.

Center Offset Adjustment Procedure

Adjusts copy image position and center offset when scanning a document.

Copy Density Adjustment Timing

Specifies when the copy density adjustment should be performed.

Notes for Copy Density Adjustment

Important considerations before performing copy density adjustment.

Tools for Copy Density Adjustment

Lists the necessary tools and test charts for copy density adjustment.

Copy Density Adjustment Features

Describes the features utilized for copy density adjustment.

Copy Density Adjustment Procedure

Step-by-step procedure for adjusting the copy density.

High Voltage Adjustment Procedures

Procedures for adjusting high voltage components like the main charger.

Main Charger (Grid Bias) Adjustment

Procedure for adjusting the main charger grid bias voltage.

DV Bias Check Procedure

Procedure for checking the DV bias voltage.

Duplex Adjustment Procedures

Procedures for adjusting duplex copy settings.

Paper Reverse Position for Duplex Copy

Adjusts the reverse position for duplex copying.

Trailing Edge Void Adjustment for Duplex Copy

Adjusts the trailing edge void in duplex copy mode.

SPF Scan Position Automatic Adjustment

Automatically adjusts the SPF scan position for optimal scanning.

SPF Sub Scanning Magnification Ratio Adjustment

Adjusts the magnification ratio in the SPF sub scanning direction.

Automatic Black Level Correction

Corrects the black level for optimal white balance adjustment.

Simulation and Trouble Codes

Entering Simulation Mode

Details the key sequence required to enter the service simulation mode.

List of Simulations

A comprehensive list of available simulation modes and their operations.

Contents of Simulations

Detailed descriptions of various simulation modes and their functions.

Optical and SPF Simulations

Details simulations for mirror scanning, SPF aging, and sensor checks.

High Voltage and Duplex/Toner Motor Simulations

Covers simulations for high voltage, duplex motor, and toner motor operations.

Trouble Reset and Counter Simulations

Explains simulations for resetting troubles, checking counters, and clearing counts.

Various Setup and Configuration Simulations

Details simulations for various system setups like SPF, duplex, and destination.

Copy Lamp and Feed Solenoid Simulations

Explains simulations for copy lamp and paper/resist solenoids.

Warm-up, Aging, and Bias Simulations

Covers simulations for warm-up, aging, developing bias, and charger operations.

Duplex Motor and Toner Motor Simulations

Details simulations for duplex and toner motor operations.

Counter Display and Clear Simulations

Explains simulations for displaying and clearing various counters.

Motor Operation and SPF Setup Simulations

Covers simulations for main motor operation, polygon motor, and SPF setup.

Cassette, Duplex, and Destination Setup Simulations

Details simulations for setting up cassettes, duplex, and destination.

Machine Conditions and Void/CE Mark Setup Simulations

Covers simulations for machine conditions, void setup, and CE mark control.

Drum Life Stop Cancel and Memory Simulations

Explains simulations for canceling drum life stops and checking memory capacity.

Polygon Motor OFF Time Setup

Allows setting the polygon motor OFF time after printing.

Transfer Timing and Side Void Setup Simulations

Covers simulations for transfer timing and side void adjustments.

Energy-Save Lamp and Paper Sensor Simulations

Explains simulations for energy-save lamp and paper sensor status.

OC Cover Float Detection Simulations

Details simulations for OC cover float detection level and margin settings.

Fusing Temperature Setting Simulations

Covers simulations for setting fusing temperature in various copy modes.

Copy Density Adjustment (300dpi)

Procedure to set copy density for 300dpi resolution in different modes.

Copy Density Adjustment (600dpi)

Procedure to set copy density for 600dpi resolution in different modes.

Image Contrast Adjustment (300dpi)

Procedure to set image contrast for 300dpi resolution.

Exposure Mode Setup Simulations

Allows setting gamma table or AE operation modes, and PHOTO image process settings.

SPF Exposure Correction Simulation

Adjusts exposure correction quantity in SPF mode via Vref voltage.

Image Contrast Adjustment (600dpi)

Procedure to set image contrast for 600dpi resolution.

AE Limit Adjustment Simulation

Sets AE and AE (toner save) limit values.

Image Sharpness Adjustment Simulation

Adjusts image clarity and shading-off in each mode.

Copier Color Reproduction Setup Simulation

Sets color reproduction for each mode, selecting easily or difficult-to-copy colors.

Magnification Ratio Adjustment Simulations

Adjusts magnification ratios for main scanning and SPF sub scanning.

Flash ROM Program Writing Mode

Puts the machine into Flash ROM writing mode for program updates.

Lead Edge Image Position Adjustment

Adjusts copy image position and lead edge void quantity.

SPF Copy Lead Edge Position Adjustment

Adjusts SPF copy lead edge position.

Center Offset Adjustment Simulation

Adjusts copy image position and center offset when scanning.

Memory Reverse Position Adjustment for Duplex Copy

Adjusts reverse memory copy operations for duplex copying.

Duplex Copy Rear Edge Void Adjustment

Adjusts the rear edge void quantity in duplex copy.

Resist Quantity Adjustment Simulation

Adjusts contact pressure against resist rollers.

SPF Scan Position Automatic Adjustment

Automatically adjusts the SPF scan position for optimal scanning.

Polygon Motor Check Simulation

Performs a check of the polygon motor's HSYNC output.

Shading Check Simulation

Displays the detection level of the white board for shading.

Black Level Automatic Correction

Corrects the black level for optimal white balance adjustment.

Light Quantity Stabilization Time Setting

Sets wait time before light quantity level stabilization.

Light Quantity Stabilization Band Setting

Sets the band for light quantity stabilization.

Trouble Codes List

Lists all error codes that may occur during operation.

Details of Trouble Codes

Provides detailed explanations and remedies for various trouble codes.

Memory, LSU, and Shading Trouble Codes

Details trouble codes related to memory, LSU, and shading issues.

Lamp, Thermistor, and Heat Roller Trouble Codes

Explains trouble codes for copy lamp, thermistor, and heat roller.

Feeding and Motor Lock Trouble Codes

Details trouble codes for feeding errors and motor lock detections.

EEPROM and Counter Trouble Codes

Covers trouble codes related to EEPROM errors and counter checks.

White Shading and Laser Output Trouble Codes

Details trouble codes for white shading errors and abnormal laser output.

Copy Lamp and Thermistor Trouble Codes

Explains trouble codes for copy lamp and thermistor issues.

Heat Roller Temperature Trouble Codes

Covers trouble codes for high and low heat roller temperatures.

Feeding and Motor Lock Trouble Codes

Details trouble codes related to feeding issues and motor lock detections.

Scanner and Polygon Motor Lock Trouble Codes

Explains trouble codes for scanner return and polygon motor lock issues.

EEPROM and Counter Error Codes

Covers trouble codes for EEPROM read/write errors and counter check sums.

User Program Settings

Toner Save and Power Save Modes

Explains how to set toner save mode and the two power save modes.

Auto Clear and Resolution Settings

Details setting the auto clear time and copy resolution for AUTO/MANUAL modes.

User Program Number and Parameter Configuration

Explains how to set and change various user program parameters.

Prevention of OC Copies and Paper Width Settings

Covers user programs for preventing OC copies and setting paper width.

Copy Start State and Fusing Temperature Settings

Details user programs for copy start state and fusing temperature.

Electrical Section

Overall Block Diagram

Presents a high-level block diagram of the copier's electrical system.

AL-2030 MCU PWB Wiring Diagram (1/2)

Shows the wiring connections for the AL-2030 MCU PWB.

AL-2030 SPF Unit Wiring Diagram

Shows the wiring connections for the SPF unit.

AL-2030 2nd Cassette Unit Wiring Diagram

Displays the wiring connections for the 2nd cassette unit.

AL-2040CS NIC PWB Wiring Diagram

Shows wiring for the NIC PWB (network interface).

AL-2040CS MCU PWB Wiring Diagram (1/4)

Shows the wiring connections for the AL-2040CS MCU PWB.

AL-2040CS SPF Unit Wiring Diagram (2/4)

Shows wiring for the SPF unit.

AL-2040CS 2nd Cassette Unit Wiring Diagram (3/4)

Displays wiring for the 2nd cassette unit.

AL-2040CS NIC PWB Wiring Diagram (4/4)

Shows wiring for the NIC PWB.

Signal Name List

A reference list of signals, their names, functions, and sections.

MCU PWB CPU Section Diagram

Schematic diagram of the MCU PWB's CPU section.

MCU PWB Graphic ASIC Section Diagram

Schematic diagram of the MCU PWB's Graphic ASIC section.

MCU PWB Memory Section Diagram

Schematic diagram of the MCU PWB's memory section.

MCU PWB Driver Section 1 Diagram

Schematic diagram of the MCU PWB's driver section 1.

MCU PWB Driver Section 2 Diagram

Schematic diagram of the MCU PWB's driver section 2.

MCU PWB Driver Section 3 Diagram

Schematic diagram of the MCU PWB's driver section 3.

MCU PWB Noise Filter/Pull-up Section Diagram

Schematic diagram of the MCU PWB's noise filter and pull-up circuits.

MCU PWB Connector Section 1 Diagram

Schematic diagram of the MCU PWB's connector section 1.

MCU PWB Connector Section 2 Diagram

Schematic diagram of the MCU PWB's connector section 2.

MCU PWB Scanner I/F Section Diagram

Schematic diagram of the MCU PWB's scanner interface section.

MCU PWB USB2.0 I/F Section Diagram

Schematic diagram of the MCU PWB's USB2.0 interface section.

MCU PWB CRUM I/F Section Diagram

Schematic diagram of the MCU PWB's CRUM interface section.

MCU PWB NIC Interface Section Diagram

Schematic diagram of the MCU PWB's network interface section.

OPE PWB (7SEG) Diagram

Schematic diagram of the Operation Panel (OPE) PWB with 7-segment display.

Power Supply Diagram

Schematic diagram of the copier's power supply unit.

Lead-Free Solder Information

Lead-Free Solder Usage Notes

Provides notes on using lead-free solder thread and soldering techniques.

Safety Precautions

Caution for Battery Replacement

Important safety information regarding battery replacement.

Caution for Battery Disposal

Important safety information regarding battery disposal.

Copyright and Trademarks

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