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

This July 2002 Sharp factory service manual covers the AR-122E, AR-152E, AR-153E, and AR-157E digital laser copier/printer family. Published for after-sales service only, it is shop-level material suited to qualified copier technicians who can work with service simulations, test charts, electrical measurements, and energized-system precautions.

• Document identity: a 131-page PDF in total—130 pages of Sharp service content plus a one-page third-party notice inserted ahead of the manual. The Sharp publication carries document code 00ZAR157E/A1E.
• Model and option coverage: distinguishes single- and multi-bypass machines, the AR-153E’s optional SPF and second cassette, and the AR-157E’s standard RSPF, second cassette, memory, and automatic duplex configuration.
• Process-section repair work: covers drum replacement, cleaning-blade and felt installation, transfer-charger removal, charger-wire cleaning and replacement, and developer/toner-unit installation.
• Optical and fuser service: provides removal and assembly coverage for the CCD carriage, copy lamp, lens unit, LSU, thermistor, heater lamp, heat and pressure rollers, separator pawls, and fuser paper sensor.
• Paper handling and feeder repair: details tray and manual-feed mechanisms, paper-exit and resist components, the second-cassette feed assembly, plus RSPF-only duplex-motor, reverse-roller, pickup, clutch, solenoid, sensor, and transport assemblies.
• Factory checks and calibration: includes service simulations for loads and sensors, high-voltage outputs, fuser control, counters, Flash ROM writing, image density and sharpness, scan magnification, black level, lead-edge and center positioning, duplex reverse position, and SPF scan position.
• Electrical fault tracing: supplies system block diagrams, MCU/ASIC signal tables, circuit descriptions, five circuit-diagram groups, and a seven-sheet actual-wiring set.

Exact Model and Option Coverage

The configuration matrix separates the 12-cpm AR-122E from the 15-cpm AR-152E, AR-153E, and AR-157E. The first two use a single-sheet bypass and accept the AL-12PKM color-scanner/GDI-printer option. The AR-153E adds a multi-bypass, optional AR-SP5 SPF, optional AR-D16 second cassette, and AR-PG2 scanner/printer option. The AR-157E pairs the multi-bypass with a standard second cassette, RSPF, automatic duplexing, 16 MB of memory, and the AR-PG2 option. PCL printing and fax are not listed for these four configurations.

Coverage extends to both AB- and inch-system machines and the listed 100-, 110-, 120/127-, 230-, and 240-volt versions. The publication organizes procedures by model, installed option, and destination setup rather than by serial-number break.

Workshop Procedures and Service Data

The opening chapters explain the complete electrostatic copy cycle and map the scanner, laser, drum, developing, transfer, separation, cleaning, fusing, and paper-transport functions. Component-location material identifies motors, solenoids, sensors, switches, and each PWB before repair work begins. Regional consumables tables provide toner, developer, and drum product numbers, package information, life categories, and production-lot identification; a separate maintenance table ties the developing and process sections to service counters and display behavior.

Optical adjustment covers main- and sub-scan magnification, image start and void positions, center offset, copy density, and high-voltage checks. The duplex chapter adds memory reverse-position and trailing-edge void adjustments for RSPF operation. Sharp gray charts UKOG-0162FCZZ and UKOG-0089CSZZ, along with the Kodak Gray Scale, are identified for density and scan calibration.

The manual warns that disconnecting or reconnecting the MCU-to-LSU harness at CN119 while power is on can destroy the IC inside the LSU; residual voltage also remains briefly after shutdown. During drum repair, incorrect felt placement or drum contact can scratch or bend the sub blade or break its edge, and the detection gear must be indexed correctly when the cover is installed.

Diagnostics and Circuit Documentation

The simulation section goes beyond code definitions by identifying which installed configurations support each test. The trouble table isolates E7 memory, HSYNC, CCD, shading, and laser-output faults; F5 copy-lamp faults; H2/H3/H4 fuser faults; L1/L3 scanner-feed and return faults; L4 main-motor lock; L6 polygon-motor lock; and U2 EEPROM errors.

Circuit examples include the MCU PWB, Operation PWB, Power Supply, and Noise Filter Circuit schematics, plus Scanner Unit and SPF/RSPF Unit actual-wiring sheets. CPU and image-process ASIC pin tables connect those diagrams to motors, sensors, solenoids, heaters, 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. For laser optical faults, Sharp specifies replacement of the optical unit as an assembly rather than component-level repair.