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Remanufacturing the Sharp AL-1000 Digital Laser Copier/Printers

  • Apr 01, 2000
In August 1998, Sharp® released the AL-1000 family of digital laser copier/printers. The series consisted of three machines: AL-1000, AL-1010 and AL-1041. All featured a copy speed of 10 pages-per-minute (ppm) while models upgraded to be printer-capable models output prints at 8 ppm. The base AL-1000 and AL-1010 models offered a user-installed printer capability upgrade. The high-end AL-1041 model included printer capabilities and a "scan once/print many" feature. Targeted at copier users in small businesses and home offices, the series was distributed through superstores, catalogs and warehouse clubs. Sharp later used the same engine for an AL-1200 series, which offered the same capabilities as the AL-1000 machines at an increased copy speed of 12 ppm.

Released in November 1998, the Xerox® Document WorkCentre XD100/102 digital copier/printers use the same 600-dpi Sharp engine found in the AL-1000/1010/1041 line. Unlike the Sharp machines, Xerox shipped all XD models with the printing capability installed. The XD offered a copy speed of 10 ppm and a print speed of 8 ppm. Aimed at small office and home users, Xerox has aggressively marketed the XD100 series through superstores, catalogs and wholesale distribution and dealer channels. The combination of rising placements and high cartridge list prices makes this engine an attractive remanufacturing opportunity.

This engine features a dual-component developing system with separate drum and toner cartridges. The toner and developer are both housed in the toner cartridge and have OEM fill weights of 215g and 190g respectively. The XD100 series ships with a starter cartridge.

The assembly and disassembly of the cartridges is fairly easy. The wiper blade is made of polyurethane attached to a metal stamping. The steel doctor blade is in a fixed position. The developer roller has an aluminum sleeve with a silver coating. It is important to note that although the Sharp and Xerox cartridges use the same internal components, the cartridges are not interchangeable among printers without modification.

Disassembly of the Toner Unit

  1. Remove the two screws that secure the waste bin (Fig. 1). Remove the waste bin (Fig. 2).


    Fig. 1


    Fig. 2

  2. Remove the two screws that secure the end plate (Fig. 3).


    Fig. 3

  3. Pull out the top of the end plate, releasing the locking tabs on the bottom of the cartridge (Fig. 4). Remove the end plate.


    Fig. 4

  4. Remove the two screws that secure the developer section to the toner section (Fig. 5).


    Fig. 5

  5. Carefully separate the developer section from the toner section (Fig. 6).


    Fig. 6

  6. Thread the large end of the XD hopper cap removal tool into the toner hopper cap in a counterclockwise direction (Fig. 7).


    Fig. 7

  7. Remove the toner hopper cap (Fig. 8).


    Fig. 8

  8. Thread the small end of the hopper cap removal tool into the developer cap in a counterclockwise direction (Fig. 9).


    Fig. 9

  9. Remove the developer cap (Fig. 10).


    Fig. 10

  10. Clean the toner section with dry, filtered compressed air (Fig. 11).


    Fig. 11

  11. Clean the developer section with dry, filtered compressed air, rotating the developer roller to remove all remaining developer (Fig. 12).


    Fig. 12

Reassembly of the Toner Unit

  1. Reattach the developer section to the toner section and secure with two screws (Fig. 13).


    Fig. 13

  2. Fill the toner chamber with toner and replace the hopper cap (Fig. 14).


    Fig. 14

  3. Fill the developer chamber with developer and replace the developer cap (Fig. 15).


    Fig. 15

  4. To replace the end plate, first position the locking tabs on the bottom of the plate into the corresponding slots on the cartridge; then press the top of the plate into position (Fig. 16).


    Fig. 16

  5. Secure the end plate with two screws (Fig. 17).


    Fig. 17

  6. Replace the waste bin and secure with two screws (Fig. 18).


    Fig. 18

Disassembly of the Drum Unit

  1. There are four locking tabs that secure the green drive gear cover (Fig. 19). Squeeze the cover as shown in Fig. 20 to release the tabs, then remove the cover.


    Fig. 19

    Fig. 20

  2. Use a small flathead screwdriver to rotate the locking hub on the drum axle from the lock position (Fig. 21) to the release position (Fig. 22).


    Fig. 21


    Fig. 22

  3. Pry the drum axle loose with a screwdriver and remove (Fig. 23).


    Fig. 23

  4. Remove the OPC drum, being careful to handle it by the drum gear and the opposite end with a lint-free cleaning cloth or latex gloves (Fig. 24).


    Fig. 24

    If you plan to reuse the drum, store in an area protected from light and impact damage. Clean the drum with dry, filtered compressed air.

  5. Remove the two screws that secure the corona wire assembly (Fig. 25).


    Fig. 25

  6. Pull the housing out slightly with your left hand as shown in Fig. 26. Lift up the right end bracket and slide the corona wire assembly out to the right (Fig. 27). Clean the assembly with dry, filtered compressed air.


    Fig. 26


    Fig. 27

  7. Remove the two screws that secure the wiper blade (Fig. 28). Remove wiper blade and clean with dry, filtered compressed air.


    Fig. 28

  8. Clean the toner unit housing with dry, filtered compressed air including all felt and foam sealing components (Fig. 29).


    Fig. 29

Reassembly of the Drum Unit

  1. Replace the wiper blade and secure with two screws (Fig. 30).


    Fig. 30

  2. Replace the corona wire assembly, sliding the left end in first and then press the right end bracket into position (Fig. 31). Secure the assembly with two screws (Fig. 32).


    Fig. 31


    Fig. 32

  3. Replace the OPC drum. Place the geared end into the corresponding hole on the housing and then lower the opposite end into position (Fig. 33).


    Fig. 33

  4. Replace the drum axle and then rotate the drum axle hub into the lock position (Fig. 34).


    Fig. 34


    Fig. 34a

  5. Reinstall the drive gear end cover (Fig. 35).


    Fig. 35

  6. Rotate the gear in the slot on the end cover (Fig. 36) until the tab is all the way down in the starting position (Fig. 37).


    Fig. 36


    Fig. 37

For further information, contact Static Control Components Technical Support at 800-488-2426, 919-774-3808 or fax 800-488-2452 or 919-774-1287. The company website can be accessed at www.scc-inc.com.




Xerox XD100 Engine Information
Engine Name Sharp AL-1000
Engine Type Monochrome Digital Laser Copier/Printer
Date of Printer Introduction August 1998
Print Speed 10 cpm (copies)/8 ppm (printing)
Duty Cycle 1,000 pages/month
Print Resolution 600x600 dpi
Xerox XD100 Printer Compatibility
Xerox WorkCentre XD 100/102/103F/120F/155F
Sharp AL-1000/1010/1041/1200/1220/1250/1521
Xerox XD100 Cartridge Information
Toner Cartridge OEM Part Number 6R914 (Xerox)
AL-100TD (Sharp)
Cartridge List/Wholesale Price* $187/$179 (Xerox)
$250/$208 (Sharp)
OEM Rated Page Yield 6,000 pages
Drum Cartridge OEM Part Number 13R551 (Xerox)
AL-100DR (Sharp)
Cartridge List/Wholesale Price* $198/$165 (Xerox)
$270/$214 (Sharp)
OEM Rated Page Yield 18,000 Pages
*Prices as of February 2000



Click to view enlarged photo.


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This article originally appeared in the April 2000 issue of Recharger.

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