Disassembly Instructions for the Sharp AR-152 Toner Cartridges
First released in January 2001, the Sharp AR-152 engine is an 8 to 15 ppm digital
copier engine that runs at 600 dpi. Unlike all other small Sharp copiers, the
toner cartridge is separate from the developer unit. The toner unit has a chip
in it that must be replaced. The developer unit and the drum units are not user
replaceable. According to Sharp, the units must be replaced/rebuilt by Sharp
technicians. These instructions cover the toner and developer units. The drum
unit will be covered in a later article.
Both the toner unit and the developer units are very easy to rebuild. Since
the toner unit is user replaceable, extra used toner cartridges will be available.
However, you will need to rebuild the developer units in the field. Sharp sells
the developer in 170g bags just for that purpose. New developer units are not
readily available even through Sharp dealers.
When it is new, the toner unit comes with a tape seal across the long toner
slot and a plastic seal in the waste hopper. See Figures 1 and 2. The plastic
seal across the waste chamber is useless when the cartridge is new; it only
applies after the cartridge has been used and there is toner in the waste chamber.
Curiously, there are no notes anywhere with the cartridge for the user to save
the plastic seal and use it to prevent spillage after the waste cartridge is
full and has been removed from the machine. For remanufacturing purposes, if
the customer kept the seal and you want to use it, go ahead. If it is not there,
don’t worry about it. The tape seal for the toner is also not necessary
if you are going to hand deliver the cartridge.
Machine troubleshooting/error codes as well as instructions for the developer
reset are covered at the end of this article.
The following machines are based on the AR-152:
1) Remove the three screws located on the top of the cartridge next to the
green handle. See Figure 3.
2) Lift up the cover from the handle side, slide the cover away from you and
remove. See Figure 4.
3) Vacuum/blow clean the waste chamber.
4) From below the waste chamber, remove the toner fill plug. See Figure 5.
5) Vacuum/blow clean the toner supply chamber. Make sure that you also clean
the long slit behind the spring-loaded cover where the toner is fed into the
developer section. See Figure 6.
6) Remove the two screws and the old chip from the cartridge. See Figure 7.
7) Install the new chip and two screws. See Figure 8.
8) Take the top cover and align the tabs and pins. See Figure 9.
9) Install the three screws. See Figure 10.
10) Check to see that the spring-loaded cover moves freely. See Figure 11.
11) Fill with AR-152 toner. See Figure 12.
12) Replace the fill plug, and check for leaks.
13) Open the front and right-side covers on the copier. Remove the large screw
at the base of the developer unit. Carefully remove the developer unit. See
14) The developer unit consists of two halves, the upper and lower. Remove
the single screw from the upper half. See Figure 14.
15) Carefully dump out all the old developer into an empty garbage bag and
vacuum the unit clean. (Double up on the bags in case one leaks.)
16) Carefully pour the new developer across the feed auger in the lower unit.
Be careful not to spill any outside the unit. See Figure 15.
17) Reinstall the upper unit and screw.
18) Rotate the developer drive gear in the direction indicated, which distributes
the developer evenly. See Figure 16.
19) Reinstall the developer unit and lock it in place with the large screw.
All parts are available from Sharp for the developer cartridge. Strangely,
no part number is listed for the entire developer unit.
The developer is rated for 25,000 pages. The default setting on the machine
is to keep running even after the 25,000 pages. That default setting can be
set by the dealer to stop at 25,000 pages. It is considered a dealer option.
To clear the developer after a stop, or to reset the counter, run simulation
To enter the simulation mode, press the “CLEAR KEY,” “EXPOSURE
SELECT KEY,” “CLEAR KEY,” and “EXPOSURE SELECT KEY.”
Press “PRINT.” The developer count is now cleared.
A circle with dots around it signals that the developer needs to be changed.
“CH” blinking: No toner cartridge installed.
“CH” on steady: Side door open.
Toner light on steady: Toner cartridge should be changed soon.
Toner light flashing: Toner cartridge must be changed now.
The machine codes, as listed in the service manual, are not all that helpful
for normal problems. For example, paper jams are not listed at all. I have listed
the code categories generally just as an aid. One interesting code is “F2,”
a cartridge-type error. Since Sharp is no longer making machines for Xerox,
there must be another manufacturer it is planning to work with down the line.
E codes: Seem to be all circuit-board errors.
L codes: Motor/mirror problems.
H codes: Fuser problems.
U codes: EEPROM errors.
F codes: Except for F2 explained above, fax communication errors.
Checking toner cartridge life:
To see how much life is left in the toner cartridge, press and hold the
“LIGHT” and “DARK” keys simultaneously for approximately
five seconds, or until all the lights flash and two dashes appear in the display.
Press and hold down the copy ratio display “%” for five seconds.
The approximate amount of toner left in the cartridge will display as a percentage
“100,” “75,” “50,” “25” or “10.”
When less than 10 percent is left, “LO” will be displayed.
Press either the “LIGHT” or “DARK” key and all the flashing
lights will go out.
Editor’s Note: Figures 13 through 16 were modified from original images
in the Sharp service manual.
Contact Mike Josiah and the technical staff of Summit Laser at (631) 218-8376,
fax (631) 218-3285 or visit www.summitlaser.com.
This article originally appeared in the October 2002 issue of Recharger.