Sharp AR-122E/152E/153E/157E Copier Service Manual, 2002 (P/N 00ZAR157E/A1E)

This July 2002 Sharp service manual covers the AR-122E, AR-152E, AR-153E, and AR-157E digital laser copier/printer family. Published for after-sales service, it carries P/N 00ZAR157E/A1E.

PDF Text Search and Schematic Detail

Search and navigation: Service text and most wiring labels are searchable. The power-supply schematic images and part of the battery-warning page are not. There are no embedded PDF bookmarks. Small schematic labels need zooming; lettering on the power-supply drawings is less sharp than on the MCU diagrams.

One printable English PDF contains 131 pages total: 130 pages of the Sharp publication plus one added introductory notice. The total includes the original cover, safety and copyright pages, and two blank pages.

Copier Process, Paper Transport, and Service Calibration

The following selected service topics outline the main coverage. Additional material includes installation and transport preparation, user-program settings, and toner-save setup.

• Process-section repair: Drum replacement, cleaning-blade and felt installation, transfer-charger removal, charger-wire cleaning and replacement, and developer/toner-unit installation.

• Optics and fuser: CCD carriage, copy lamp, lens unit, and LSU removal, plus internal fuser work involving the thermistor, heater lamp, rollers, separator pawls, and paper sensor.

• Paper handling: Tray and manual-feed mechanisms, paper-exit and registration components, second-cassette assemblies, and RSPF-only duplex drives, rollers, clutches, solenoids, and sensors.

• Service simulations: Load and sensor checks, high-voltage outputs, fuser control, counters, Flash ROM writing, image calibration, and configuration-dependent tests.

• Electrical diagnosis: System block diagrams, MCU/ASIC signal tables, circuit descriptions, five circuit-diagram groups, and a seven-sheet actual-wiring set.

This shop-level material is suited to qualified copier technicians who work with service simulations, test charts, electrical measurements, and energized-system precautions.

Model Configurations and Optional Kits

The AR-122E and AR-152E use a single-sheet bypass and accept the AL-12PKM color-scanner/GDI-printer option. The AR-153E has a multi-bypass, optional AR-SP5 SPF, optional AR-D16 second cassette, and AR-PG2 scanner/printer option.

The AR-157E combines a multi-bypass with a standard second cassette, RSPF, and automatic duplexing; its scanner/printer option is AR-PG2. Printer/scanner functions depend on the corresponding optional kit, and scanning uses USB. The configuration matrix excludes PCL printing and fax for these four models.

Specifications distinguish AB- and inch-system machines and list 100-, 110-, 120/127-, 230-, and 240-volt versions.

Component Repair and Maintenance

The copy-process and operational chapters explain how scanning, laser exposure, developing, transfer, separation, cleaning, and fusing interact. Component-location views identify motors, solenoids, sensors, switches, and PWBs.

Numbered step-by-step procedures cover disassembly and assembly, with specific reassembly notes for grounding springs, belt engagement, and LSU spacer selection according to scan-inclination classification.

Regional consumables tables identify toner, developer, and drum products, packaging, service-life categories, and production-lot markings. The maintenance section connects developing and process-component service with counters and indicator behavior.

LSU and drum handling: Connecting or disconnecting the MCU-to-LSU harness at CN119 while powered can destroy the LSU’s internal IC; residual voltage remains briefly after shutdown. Incorrect felt placement or drum contact can damage the sub blade, and drum-cover installation requires correct detection-gear alignment.

Image Adjustment and Post-Repair Checks

The manual links optical work, OPC drum replacement, and main-board or EEPROM replacement to the required image adjustments, helping technicians plan post-repair calibration.

Adjustment coverage includes main- and sub-scan magnification, black level, image-start and void positions, center offset, density, sharpness, and high-voltage checks. The duplex section adds memory reverse-position and trailing-edge void adjustments.

Sharp gray charts UKOG-0162FCZZ and UKOG-0089CSZZ, together with the Kodak Gray Scale, are identified for density and scan calibration.

Fault Codes and Circuit References

The trouble table distinguishes E7 memory, HSYNC, CCD, shading, and laser-output faults; F5 copy-lamp faults; and H2/H3/H4 fuser faults. Other entries address L1/L3 scanner travel, L4 main-motor lock, L6 polygon-motor lock, and U2 EEPROM errors.

Diagram examples include MCU PWB, Operation PWB, Power Supply, and Noise Filter Circuit schematics, plus Scanner Unit and SPF/RSPF Unit wiring sheets. CPU and image-process ASIC pin tables relate these references to loads, sensors, heater controls, high-voltage controls, USB/parallel interfaces, and option boards.

Disconnect power before internal repair and follow the manual’s residual-voltage, laser-exposure, and hot-fuser precautions. Laser optical-unit faults call for assembly replacement rather than repair of individual internal parts.

Selected Image-Position and Duplex Adjustment Values

For copying at nominal 100% magnification, the main- and sub-scan adjustment checks specify 100 ±1.0%. The print-center offset standard is 0 ±2 mm from the paper center.

For the AR-157E, duplex adjustment distinguishes a 4–5 mm first-surface paper trailing-edge void from a 2–4 mm RSPF image-cut trailing-edge void in duplex-to-duplex mode.