Sharp FO-DC635U User manual

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SERVICE MANUAL
OPTION
Toner cartridge: FO-50ND
Drum cartridge: FO-47DR
Option memory: FO-8MK
Verification stamp: FO-45VS
Paper cassette (2nd): FO-CS2
LAN Network interface kit: FO-LN1
Network printer kit: FO-NP1
Network scanner kit: FO-NS2
Dual line kit: FO-60DL
NOTE:
•FO-NP1 (Network Printer Kit) and FO-60DL (Dual Line Kit) can not
be mounted simultaneously.
•FO-LN1 (LAN Network Interface Kit) and FO-60DL (Dual Line Kit)
can be mounted simultaneously. However, multi-operation of
2 line communication and network scan is not possible.
Chapters 1, 2, 3, 7 and 8 of this manual are omitted because they are partly common to the FO-4470U/
FO-DC535U. Please refer to previous service manual (00ZFO4470USME) / (00ZFDC535USME) for these
chapters.
MODEL SELECTION CODE DESTINATION
FO-DC635 U U.S.A./Canada
FO-DC635U
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.
TopPage
No. 00ZFDC635USME
FACSIMILE
FO-DC635U
MODEL

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CONTENTS
CHAPTER 1. GENERAL DESCRIPTION
[1] Caution........................................................... 1-1
[2] Specifications ................................................. 1-3
[3] Operation panel.............................................. 1-4
[4] Transmittable documents............................... 1-6
[5] Installation...................................................... 1-7
CHAPTER 2. ADJUSTMENTS
[1] Adjustments ................................................... 2-1
[2] Diagnostics and service soft switches............ 2-3
[3] Troubleshooting ........................................... 2-40
[4] Error code table............................................ 2-40
[5] Overseas communication mode .................. 2-40
[6] Administrator mode in the personal book
function ........................................................ 2-40
CHAPTER 3. MECHANICAL DESCRIPTION
[1] Mechanical description .................................. 3-1
[2] Printer description .......................................... 3-1
[3] Disassembly and assembly procedures........ 3-1
[4] How to install the verification stamp (FO-
45VS) ............................................................. 3-2
CHAPTER 4. DIAGRAMS
[1] Block diagram ................................................ 4-1
[2] Wiring diagram............................................... 4-2
[3] Point-to-point diagram.................................... 4-3
CHAPTER 5. CIRCUIT DESCRIPTION
[1] Circuit description .......................................... 5-1
[2] Circuit description of control PWB .................5-1
[3] Circuit description of CIS unit ......................5-15
[4] Circuit description of LIU PWB ....................5-16
[5] Circuit description of operation panel PWB......5-18
[6] Circuit description of power supply PWB......5-19
[7] Circuit description of Dual Line Kit (Option:
FO-60DL).....................................................5-20
CHAPTER 6. CIRCUIT SCHEMATICS AND PARTS
LAYOUT
[1] Control PWB circuit .......................................6-1
[2] LIU PWB circuit ...........................................6-18
[3] Printer PWB circuit ......................................6-21
[4] Power Supply PWB circuit...........................6-25
[5] Operation Panel PWB circuit .......................6-27
[6] LCD Relay PWB circuit................................6-31
[7] 1st Paper Cassette PWB circuit ..................6-32
CHAPTER 7. OPERATION FLOWCHART
[1] G3 Protocol....................................................7-1
[2] Super G3 Protocol ......................................... 7-1
[3] Power on sequence.......................................7-1
CHAPTER 8. OTHER
[1] Service tools ..................................................8-1
[2] Rewriting version up the FLASH ROM ..........8-1
Parts Guide
FO-DC635U

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- MEMO -
FO-DC635U

FO-DC635U
1 – 1
FO-DC635U Service Manual
CHAPTER 1. GENERAL DESCRIPTION
[1] Caution
1. Laser caution
This laser printer is a class 1 laser product that complies with 21CFR 1040.10 and 1040.11 of the CDRH or IEC60825-1 standard. This means that
this machine does not produce a hazardous laser radiation. The use of controls, adjustments or performance of procedures other than those specified
herein may result in hazardous radiation exposure.
This laser radiation is not a danger to the skin, but when an exact focusing of the laser beam is achieved on the eyes retina, there is danger of spot
damage to the retina.
The following cautions must be observed to avoid exposure of the laser beam to your eyes at the time of servicing.
1) When a problem in the laser optical unit has occurred, the whole optical unit must be exchanged as a unit, not an individual part.
2) Do not look into the machine with the main switch turned on after removing the toner/developer unit and drum cartridge.
3) Do not look into the laser beam exposure slit of the laser optical unit with the connector connected when removing and installing the optical sys-
tem.
4) The cover of Laser Printer Unit contains the safety interlock switch.
Do not defeat the safety interlock by inserting wedges or other items into the switch slot.
2. Life of consumable
Laser Wave Length : 770 nm -810 nm
Laser Pulse Times : 51.3 ns
Laser Output Power Max : 5 mW
Section Part Estimated Life Replaced by
Toner cartridge Replacement cartridge
(FO-50ND)
6,000 prints (at Letter/4%
chart)
User
Drum cartridge Replacement cartridge (FO-47DR) 20,000 prints (at Letter/4%
chart)
User
Paper feed Transfer roller (Refer to the P/G No. 10-8)
(0KW4127410302)
50,000 prints Service Engineer
Fusing unit Fusing unit (Refer to the P/G No. 9-14)
(0KW4127036001)
50,000 prints Service Engineer
Paper transport Paper transfer roller (Refer to the P/G No. 8-6)
(0KW4127300101)
Cleaning as needed ———————
Unit FO-DC635 5 years or 75,000 prints of
early either
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FO-DC635U
1 – 2
3. Caution for Battery replacement
4. Precautions for using Lead-Free Solder
(Danish) ADVARSEL !
Lithiumbatteri-Eksplosionsfare ved fejlagtig håndtering.
Udskiftning må kun ske med batteri af samme fabrikat og type.
Levér det brugte batteri tilbage til leverandoren.
(English) Caution !
Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type
recommended by the equipment manufacturer.
Discard used batteries according to manufacturer's instructions.
(Finnish) VAROITUS
Paristo voi räjähtää, jos se on virheellisesti asennettu.
Vaihda paristo ainoastaan laitevalmistajan suosittelemaan
tyyppiin. Hävitä käytetty paristo valmistajan ohjeiden mukaisesti.
(French) ATTENTION
Il y a danger d'explosion s' il y a remplacement incorrect
de la batterie. Remplacer uniquement avec une batterie du
même type ou d'un type recommandé par le constructeur.
Mettre au rébut les batteries usagées conformément aux
instructions du fabricant.
(Swedish) VARNING
Explosionsfare vid felaktigt batteribyte.
Använd samma batterityp eller en ekvivalent
typ som rekommenderas av apparattillverkaren.
Kassera använt batteri enligt fabrikantens
instruktion.
(German) Achtung
Explosionsgefahr bei Verwendung inkorrekter Batterien.
Als Ersatzbatterien dürfen nur Batterien vom gleichen Typ oder
vom Hersteller empfohlene Batterien verwendet werden.
Entsorgung der gebrauchten Batterien nur nach den vom
Hersteller angegebenen Anweisungen.
1. Employing lead-free solder
This model employs lead-free solder.
This is indicated by the "LF" symbol printed on the PWB and in the service manual.
The suffix letter indicates the alloy type of the solder.
Example:
Indicates lead-free solder of tin, silver and copper.
2. Using lead-free solder
When repairing a PWB with the "LF" symbol, only lead-free solder should be used. (Using normal tin/lead alloy solder may
result in cold soldered joints and damage to printed patterns.)
As the melting point of lead-free solder is approximately 40°C higher than tin/lead alloy solder, it is recommended that a
dedicated bit is used, and that the iron temperature is adjusted accordingly.
3. Soldering
As the melting point of lead-free solder (Sn-Ag-Cu) is higher and has poorer melting point (flow), to prevent damage to the
land of the PWB, extreme care should be taken not to leave the bit in contact with the PWB for an extended period of time.
Remove the bit as soon as a good flow is achieved.
The high content of tin in lead free solder will cause premature corrosion of the bit.
To reduce wear on the bit, reduce the temperature or turn off the iron when it is not required.
Leaving different types of solder on the bit will cause contamination of the different alloys, which will alter their
characteristics, making good soldering more difficult.
It will be necessary to clean and replace bits more often when using lead-free solder. To reduce bit wear, care should be
taken to clean the bit thoroughly after each use.

FO-DC635U
1 – 3
[2] Specifications
1. GENERAL
Automatic dialing: Conventional Auto Dialing:
Rapid Key Dialing: 59 numbers, Speed
Dialing: 200 numbers
Personal Auto Dial Books: 40 books (59
Rapid Keys, 16 Speed Dial numbers per
book)
Memory size*: 16 MB (approx. 500 pages)
Optional memory: FO-8MK (8 MB;approx.
500 pages)
Modem speed: 33,600 bps (max.) with automatic fallback
to lower speeds
Transmission time*: Approx. 2 seconds
Toner cartridge yield**:
(continuous printing,
4% page coverage, let-
ter paper)
Initial starter cartridge (included with
machine): Approx. 3000 pages
Replacement cartridge (FO-50ND):
Approx. 6000 pages
Drum cartridge yield**:
(continuous printing,
4% page coverage, let-
ter paper)
Initial starter cartridge (included with
machine): 20,000 pages (avg.)
Replacement cartridge (FO-47DR):
20,000 pages (avg.)
Resolution: Standard: 203 x 98 lines/inch
(8 x 3.85 lines/mm)
Fine/Halftone: 203 x 196 lines/inch
(8 x 7.7 lines/mm)
Super fine: 203 x 391 lines/inch
(8 x 15.4 lines/mm)
Ultra fine: 406 x391 lines/inch
(16 x 15.4 lines/mm)
Halftone (grayscale): 64 levels
Automatic document
feeder:
Letter paper (20 lb): Max. 50 pages
Legal paper: Max. 20 pages (Note: 11” x
17” paper must be loaded one page at a
time.)
Paper capacity: 750 sheets (20 lb) (500-sheet cassette ava-
iable as option)
Compression scheme: MMR, MR, MH, Sharp (H2), JBIG
Applicable telephone
line:
Public switched telephone network
Applicable telephone
line:
Public switched telephone network
Compatibility: ITU-T (CCITT) G3 mode, Super G3 mode
Printing resolution: Horizontal: 406 lines/inch (16 lines/mm)
Vertical: 391 lines/inch (15.4 lines/mm)
Input document size: Automatic feeding:
Width: 5.8 to 10.1” (148 to 257mm)
Length: 5.0 to 14.3” (128 to 364 mm)
Manual feeding:
Width: 5.8 to 11.0” (148 to 279 mm),
Length: 5.0 to 38.0” (128 to 966 mm)
(mazimum length 19” (483 mm) when ultra
fine resolution is used.)
Effective scanning
width:
10” (257 mm) max.
Effective printing
width:
8.0” (203 mm) max.
Printing speed: 16 ppm
Reception modes: Auto/Manual
Instascan speed: 1.3 sec/page (letter paper; scan time only,
excludes document feeding time)
Full Dual Access: Yes
Copy function: Single/Multi/Sort (99 copies/page)
Power requirements: 120 V AC, 60 Hz
Operating tempera-
ture:
50 - 86°F(10 - 30°C)
Humidity: 20 to 85% RH
Power consumption: Stand-by: 9 W
Stand-by (all options installed): 16W
Maximum: 800 W
Dimensions: Width:21.5” (546 mm)
Depth: 16.2” (412 mm)
Height: 17.0” (431 mm)
(Not including paper tray or attachments)
Weight: Approx. 48.5 lbs. (22.0 kg)
(Not including supplies paper tray or attach-
ments)
*Based on Sharp Standard Chart at standard resolution, excluding time
for protocol signals (i.e., ITU-T phase C time only).
**The yields may vary depending on coverage and operating condi-
tions.
As a part of our policy of continuous improvement, SHARP reserves the right to make design and specification changes for product improvement
without prior notice. The performance specifications figures indicated are nominal values of production units. There may be some deviations from
these values in individual units.

FO-DC635U
1 – 4
[3] Operation panel
Display
This displays messages and prompts to help you operate
the machine. The backlight turns on whenever a key is
touched, and then automatically turns off after a preset time
if no further operations are performed. The display can be
tilted to the desired angle for easy viewing.
TONER indicator
This blinks when the toner cartridge nears empty, and lights
steadily when the toner cartridge needs replacement.
ALARM indicator
This blinks when one of the paper sources is empty, or the
drum cartridge is near or at the end of its life. This lights
steadily when all paper sources are empty, the print
compartment cover is open, or a paper jam has occurred.
A message will appear in the display to indicate the problem.
1
2
3
Q/! W/" E/# R/$ T/% Y/& U/' I/( O/) P/=
SYMBOL A/|S D F G/{ H/} J/[ K/] L/+
Caps Lock Z/< X/> C V B N/* M/? @ .com
SHIFT /^ // \ ;/: Space _- ./, DEL
Q/! W/" E/# R/$ T/% Y/& U/' I/( O/) P/=
SYMBOL A/|S D F G/{ H/} J/[ K/] L/+
Caps Lock
PAGE COUNTER CONFIDENTIAL TIMER COVER SHEET LIFE MEM.STATUS REPORT DOCUMENT
Z/< X/> C V B N/* M/? @ .com
SHIFT /^ // \ ;/: Space _- ./, DEL
01 02 03 04 05 06 07 08 09 10
11 12 13 14 15 16 17 18 19 20
40 41 42 43 44 45 46 47 48 49
50 51 52 53 54 55 56 57 58 59
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39
11
11
14 15 16 17 18 19 2012 13
DATAlight
This blinks when the machine is receiving a print job over
the network (only when the network printer option is
installed).
FAX1 / FAX2 lights
When the dual line option is installed, FAX 1 lights when
Line 1 is being used and FAX 2 lights when Line 2 is being
used. When the dual line option is not installed, only FAX 1
lights when the telephone line is being used (the FAX 2
light does not operate).
4
5
ON LINE light (printer option only)
When this light is on, the machine can receive data (print
jobs) over the network. The light is turned on or off with the
ON LINE key. (Only available when the network printer
option is installed).
CONTRAST key
Press this key to adjust the contrast before sending or
copying a document.
E-mail key
Press this key to send a scanned document to an e-mail
recipient. (Only available when the network scanner option
is installed).
RESOLUTION key
Press this key to adjust the resolution before sending or
copying a document. An indicator will light next to the
selected setting (HALFTONE, STANDARD, FINE, SUPER
FINE or ULTRA FINE).
ON LINE key (printer option only)
Press this key to select whether the machine is online or
off-line (the ON LINE light is on when the machine is
online). The machine must be online to receive print
jobs over the network. (Only available when the network
printer option is installed).
6
10
9
8
7
11
Rapid Dial Keys
Press one of these keys to dial a fax number automatically,
or specify an e-mail recipient if the network scanner option
is installed. Note that you must attach the Rapid Key labels.
When navigating through the display menu, a Rapid Key
can also be pressed in place of the numeric keys to enter
a two-digit number (for example, you can press Rapid Key
01 to enter the number "01").
SYMBOL key
When entering a name, press this key to enter the symbol
on a letter key (the character to the right of the slash).
Press the key again to turn off symbol entry mode.
PAGE COUNTER key
Press this key to include a slash and the total number of
pages after each page number on the pages of a
transmitted document.
CONFIDENTIAL key
Press this key to send or print out a confidential document.
14
12
13
JKL
ABC
1
DEF
WXYZ
9
GHI
45
MNO
6
PQRS
7
TUV
8
0
2 3
OPER
PERSONAL
BOOK
SPEED DIAL
REDIAL
SPEAKER
JOB STATUS DUPLEX SCAN PRIORITY BROADCAST
MENU
UP
ZA
DOWN
START/
ENTER
COPY
STOP
GAB SEARCH
22 2923 24 25 30282726
31 35 3632 3433
DOCUMENT COMMUNICATION SYSTEM
HALF TONE ALARM
TONER
DATA
ON LINE
Network
CONTRAST RESOLUTIONe-mail ON LINE
STANDARD
FINE
ULTRA FINE
SUPER FINE
1
7
3 5 62
98 10
FAX2FAX1
4
LINE
21

FO-DC635U
1 – 5
15
TIMER key
Press this key to set a fax operation to be performed
automatically at a later time.
COVER SHEET key
Press this key to include a cover sheet when sending a fax.
LIFE key
Press this key, followed by , to check the total number of
pages printed by the fax machine. (Press to return to the
data and time display.
MEM. STATUS key
Press this key to check the status of fax transmission jobs,
copy jobs, and fax receptions. This key can also be used to
cancel a job.
REPORT key
Press this key before sending a fax (on a Scan to E-mail/FTP/
Desktop transmission when the network scanner option is
installed) to have a transaction report printed out after the
transmission is finished.
DOCUMENT key
Press this key to transmit a document directly from the feeder
without reading it into memory.
16
18
19
17
20
23
22
START/
ENTER
STOP
JOB STATUS key
Press this key to display the FAX-STATUS screen, which
shows information on the fax job that is currently in progress.
If the dual line option is installed, the fax status will appear
separately for each line. If the network printer option is
installed, the NETWORK PRINT STATUS screen showing
information on current printer activity will appear following
the FAX STATUS screen (note that "IDLE" will appear if a
print job has been executed but is not yet being printed).
To move through each of the screens and return to the date
and time display, press one or more times as needed.
DUPLEX SCAN key
Press this key to transmit or copy a two-sided document.
PRIORITY key
Press this key when you need to transmit a document ahead
of other documents waiting in memory for transmission.
BROADCAST key
Press this key to send a document to a group of fax
machines, or to a group of e-mail recipients if the network
scanner option is installed.
24
25
26
27
JOB STATUS
PERSONAL BOOK
Press this key to use or store an auto-dial number in a
personal book. If the book has a passcode, enter the
passcode; otherwise, select the book with or and
press .
SPEED DIAL key
Press this key to dial a Speed Dial number.
MENU key
Press this key to select special functions and setting.
UP and DOWN arrow keys
Volume setting: Press these keys to change the speaker
volume when the SPEAKER key has been pressed, or the
ringer volume at any other time.
MENU key settings: Press these keys after pressing the
MENU key to scroll through the MENU key settings.
COPY key
Press this key to make a copy of a document that is in the fee
d
29
30
28
START/
ENTER
Dial keypad (numeric keys)
Use these keys to dial and program fax numbers.
REDIAL key
Press this key to automatically redial the last number dialed.
SPEAKER key
Press this key when faxing a document by Normal Dialing to
listen to the line and verify the response of the receiving fax
machine.
START/ENTER key
Press this key to begin fax transmission when using Speed
Dialing, Direct Keypad Dialing, or Normal Dialing. This key is
also used to select settings in the MENU key menu and
complete entries when storing names and numbers.
Left and right arrow keys
Press these keys to search for an auto-dial number when
sending a document. If the network scanner option is installed
and your network has an LDAP server, the left arrow key
(GAB SEARCH) can be pressed to search for a destination on
the LDAP server. (Note: "GAB" stands for "Global Address
Book".)
STOP key
Press this key to cancel an operation before it is completed.
31
32
33
34
35
36
LINE key
When the dual line option has been installed, press this key
before dialing to select the line.
21

FO-DC635U
1 – 6
[4] Transmittable documents
1. Document Sizes
• With special sizes, only one sheet can be fed into the machine at a
time. Insert next page into feeder as current page is being scanned.
2. Paper Thickness & Weight
3. Document Types
• Normal paper
Documents handwritten in pencil (No. 2 lead or softer), fountain
pen, ball-point pen, or felt-tipped pen can be transmitted.
Documents of normal contrast duplicated by a copying machine
can also be transmitted.
• Diazo copy (blue print)
Diazo copy documents of a normal contrast may be transmitted.
• Carbon copy
A carbon copy may be transmitted if its contrast is normal.
4. Cautions on Transmitting Documents
• Documents written in yellow, greenish yellow, or light blue ink can-
not be transmitted.
• Ink, glue, and correcting fluid on documents must be dry before the
documents can be transmitted.
• All clips, staples and pins must be removed from documents before
transmission.
• Patched (taped) documents should be copied first on a copier and
then the copies used for transmission.
• All documents should be fanned before insertion into the feeder to
prevent possible double feeds.
5. Automatic Document Feeder Capacity
Number of pages that can be placed into the feeder at anytime is as
follows:
Normal size: max. 50 sheets (14 lbs - 20 lbs)
Special size: single sheet only (manual feed)
NOTE: •If you need to send or copy more 50 pages, place the addi-
tional pages and carefully in the feeder just before the last
page is scanned. Do not try to force them in, as this may
cause double-feeding or jamming.
•If your document consists of several large or thick pages
which must be loaded one at a time, insert each page into the
feeder as the previous page is being scanned. Insert gently to
prevent double feeding.
6. Readable Width & Length
The readable width and length of a document are slightly smaller than
the actual document size.
Note that characters or graphics outside the effective document scan-
ning range will not be read.
•Readable width
10” (257mm), max
•Readable length
This is the length of the document sent minus 0.16” (4mm) from the
top and bottom edges.
Normal size Width 5.8” - 10.1”(148 - 257 mm)
Length 5.0” - 14.3”(128 - 364 mm)
Product specifications
Indication Lower Limit Upper Limit
Weight indi-
cation
Japanese indi-
cation Size 4 x 6
45kg paper 70kg paper
Metric system
indication
52g/m280g/m2
American indi-
cation LB sys-
tem indication
14 LB 20 LB
Thickness
indication
Metric system
indication
0.06mm 0.1mm
Inch system
indication
0.0024" 0.0035"
Document
size
Document size
Range
(148mm x 128mm) ~
W letter (279mm x 483mm)
A4 (210mm x 297mm)
Letter (216mm x 279mm)
Number of
ADF sheets
Document size
Weight
B6 ~ Letter/A4 size 50sheets
B4 size/Legal 20sheets
W letter size 1sheet
90 kg (104g/m2) or more
135 kg (157g/m2) or less 1sheet
Paper qual-
ity
Kind Paper of fine quality/bond paper/
Kent paper
(Min.)
(Max.)
(Max.)
128mm
364mm
966mm
148mm 257mm
[Normal size]
279mm
[Special size]
Readable width
0.16" (4mm)
0.16" (4mm)
Readable length

FO-DC635U
1 – 7
[5] Installation
1. Site selection
Take the following points into consideration when selecting a site for
this model.
ENVIRONMENT
• The machine must be installed on a level surface.
• Keep the machine away from air conditioners, heaters, direct sun-
light, and dust.
• Provide easy access to the front, back, and sides of the machine.
In particular, keep the area in front of the machine clear, or the orig-
inal document may jam as it comes out after scanning.
• The temperature should be between 50 - 86°F (10 - 30°C).
• The humidity should be between 20% and 85% (without conden-
sation).
ELECTRICITY
AC 120V, 60Hz, grounded AC (3-prong) outlet.
Caution!
• Connection to a power source other than that specified will cause
damage to the equipment and is not covered under the warranty.
• If your area experiences a high incidence of lightning or power
surges, we recommend that you install a surge protector for the
power and telephone lines. Surge protectors can be purchased at
most telephone specialty stores.
TELEPHONE JACK
A standard telephone jack must be located near the machine. This is
the telephone jack commonly used in most homes and offices.
• Plugging the fax machine into a jack which is not an RJ11C jack
may result in damage to the machine or your telephone system. If
you do not know what kind of jack you have, or need to have one
installed, contact the telephone company.
If the machine is moved from a cold to a warm place...
If the machine is moved from a cold to a warm place, it is possible that
the reading glass may fog up, preventing proper scanning of docu-
ments for transmission. To remove the fog, turn on the power and wait
approximately 2 hours before using the machine.
2. Assembly and connections
1) Connecting the power cord
Connect the female end of the power cord to the fax machine as
shown. Insert the male end into a 120 V, 60 Hz, grounded (3-prong)
AC outlet.
Important!: The fax machine requires its own dedicated power out-
let. The power outlet must not be shared with any other devices. In
particular, do not use an extension cord to connect multiple devices
to the outlet.
Note: If your area experiences a high incidence of lightning or
power surges, we recommend that you install surge protectors for
the power and telephone lines. Surge protectors can be purchased
at most telephone specialty stores.
2) Connecting the telephone line cord
Insert one end of the line cord into the jack on the back of the
machine marked TEL. LINE. Insert the other end into a standard
(RJ11C) single-line wall telephone jack.
Note: The fax machine is set for touch-tone dialing. If you are on a
pulse dial (rotary) line, you must set the fax machine for pulse dial-
ing by changing Option Setting 22.
3) Attaching the ADF exit tray
Insert the protrusion on the right side of the machine into the hole in
the right side of the ADF exit tray , then bend the tray
slightly and insert so that the protrusion on the left side of the
machine goes into the hole on the left side of the ADF exit tray
. Pull out the tray extension .
4) Attaching the received document tray
Slide the received document tray into the machine as shown. When
it stops, lift the end slightly and push in so that the tray locks into
place.
Important!: The received document tray must be attached for the
fax machine to operate properly.
Press the power
switch to turn on
the power.
1
23
1
3
2

FO-DC635U
1 – 8
3. Installing the print cartridges (Toner cartridge:
FO-50ND)(Drum cartridge: FO-47DR)
Follow the steps below to install or replace the toner and drum car-
tridges.
• The initial starter toner cartridge included with the fax machine can
print approximately 3000 letter-size pages (4% coverage of each
page; continuous printing).
• The replacement toner cartridge (FO-50ND) can print approxi-
mately 6000 letter-size pages.
• The drum cartridge (FO-47DR) can print approximately 20,000 let-
ter-size pages.
1) Press the cover release to open the print compartment cover.
•Caution! The fusing unit inside the print compartment becomes
very hot during operation. Be careful not to touch the inside of the
compartment.
2) If you are replacing the toner cartridge, remove the old cartridge
and dispose of it according to local regulations.
Go directly to STEP 5 if you are only replacing the toner cartridge
and not the drum cartridge.
To make the cartridge more compact for disposal, press the buttons
on the ends of the handle and fold the handle down.
• If you are replacing the drum cartridge but not the toner car-
tridge, remove the toner cartridge and place it on a sheet of
paper.
3) If you are replacing the drum cartridge, remove the old cartridge
and dispose of it according to local regulations.
4) Remove the new drum cartridge from its packaging. Insert the drum
cartridge into the print compartment.
•Caution! Excessive exposure to light will damage the drum car-
tridge. Install the cartridge promptly after removing it from its
packaging.
• Make sure the drum cartridge is inserted in as far as it will go.
5) If you are installing a new toner cartridge, remove the new toner
cartridge from its packaging. Remove the tape from the cartridge
and then open the cartridge handle so that it stands straight up.
6) Shake as indicated by the arrows to distribute the toner evenly
within the cartridge.
• If the toner is still lumpy after shaking, the gears in the cartridge
may make a noticeable sound when the print compartment
cover is closed after installing the cartridge. This is normal and
does not indicate a problem.
GREEN
BLUE

FO-DC635U
1 – 9
7) Hold the toner cartridge by the handle and insert it into the print
compartment.
• Make sure the toner cartridge clicks into place.
• The handle can be left standing up.
8) Close the print compartment cover.
9) Reset the drum counter by pressing (flip up the Rapid Key
overlay), or until DRUM COUNTER CLEAR is selected
in the display, and then .
•Note: The toner counter automatically resets each time you
replace the toner cartridge. There is normally no need to reset
the toner counter manually. Should you find it necessary to
manually reset the toner counter, press (flip up the
Rapid Key overlay), or until TONER COUNTER
CLEAR is selected, and then .
Note: The print compartment cover may become noticeably
warm if a large number of pages are successively printed. This
is normal and does not indicate a problem in the machine.
10)When to replace the toner cartridge
When the toner cartridge nears empty (about 100 pages can still be
printed), the toner cartridge indicator on the operation panel will
blink. When the toner cartridge is empty, the toner cartridge indica-
tor will light steadily and REPLACE TONER CARTRIDGE will
appear in the display. Printing will no longer be possible. Use the
following replacement toner cartridge.
Sharp FO-50ND toner cartridge
Hint: When the toner cartridge nears empty, try taking it out of the
machine and shaking it. This may increase the number of pages
that can be printed before the toner runs out.
11)When to replace the drum cartridge
When the drum cartridge nears the end of its life, the ALARM indi-
cator on the operation panel will blink and REPLACE DRUM CAR-
TRIDGE will appear in the display. (this message first appears
when approximately 1000 pages before the drum needs replace-
ment). Use the following replacement drum cartridge.
Sharp FO-47DR drum cartridge
4. Loading printing paper
You can load up to 250 sheets of letter or legal paper (max. 20 lbs.) in
the paper tray. Depending on the model, a paper cassette is also
included as a standard fearure or available as an option. Up to 500
sheets of letter or legal paper can be loaded in the paper cassette.
• One paper cassette is inclued as a standard feature. A second
paper cassette is available as an option. To have a second cassette
installed, consult your dealer.
Important: Do not use the back side of paper that has already
been printed on.
Note: If you need to add paper to the tray or cassette while paper
still remains, remove the remaining paper and combine it into a sin-
gle stack with the new paper.
Loading paper in the paper tray
1) Remove the received document tray.
2) Insert a stack of paper into the tray, print side up.
•Important! The stack of paper must not be higher than the red
line on the paper tray.
3) Squeeze the paper guide and move it to match the length of the
paper you are loading.
GREEN
BLUE
LIFE
V
START/
ENTER
LIFE
V
START/
ENTER
Red line
Attach a letter or
legal label here to
indicate the paper size.

FO-DC635U
1 – 10
4) Replace the received document tray.
• The received document tray must be attached for the machine
to operate properly.
5. Loading paper in the paper cassette
Note: To use A4 paper in the paper cassette, you must have a service
technician adjust the cassette.
1) Grasp the hand-hold on the cassette and pull the cassette out until
it stops.
2) Push the pressure plate down until it locks into position.
3) Squeeze the paper guide and pull up to move it to the appropriate
holes for the length of the paper. Push the guide down into the
holes.
4) Place a stack of paper in the cassette, print side up.
• Make sure the stack of paper is not higher than the two tabs on
the paper guide and the two metal tabs. If it is, remove some of
the paper.
• If you find it difficult to load the paper, remove the cassette from
the machine. (Pull the cassette out as far as it will go, grasp the
left side of the cassette with your left hand, and then lift it up and
out with both hands.)
5) Push the cassette back into the machine, making sure it clicks into
place.
6. Clearing paper jams
Clearing a jammed document
If the original document doesn’t feed properly during transmission or
copying, or REMOVE ORIGINAL(S) appears in the display, fist try
pressing . If the document doesn’t feed out, open the opera-
tion panel and remove it.
Important: Do not try to remove a document without opening the oper-
ation panel. This may damage the feeder mechanism.
1) Open the operation panel.
• Squeeze the release marked PANEL RELEASE and pull up.
2) Remove the document.
1
2
START/
ENTER

FO-DC635U
1 – 11
3) Close the operation panel, making sure it clicks into place.
7. Clearing a jammed printing paper
If the printing paper jams, PAPER JAM will appear in the display. Fol-
low the steps below to clear the jam.
1) Press the green release and open the print compartment cover.
•Caution! The fusing unit inside the print compartment becomes
very hot during operation. Be careful not to touch the inside of
the compartment.
2) Remove the toner cartridge and place it on a sheet of paper.
3) Remove the drum cartridge.
4) Remove the jammed paper.
• Make sure no torn pieces of paper remain in the print compart-
ment and rollers.
5) Replace the drum cartridge.
• Make sure the drum cartridge is inserted in as far as it will go.
6) Replace the toner cartridge and then close the print compartment
cover.
7) If you have a paper cassette and the display still indicates that
paper is jammed, pull out the cassette and remove the jammed
paper.
8) Replace the paper cassette.
OR
GREEN
BLUE
GREEN
BLUE

FO-DC635U
1 – 12
8. Replacing the Verification Stamp (FO-45VS)
If you are using the Verification Stamp function, you will need to
replace the ink cartridge in the stamp unit when it runs out of ink (when
the stamped mark on original documents becomes faint). A new ink
cartridge can be obtained from your dealer.
1) Remove the ADF exit tray.
2) Press down on the protruding tab of the green ink cartridge and pull
the cartridge out with your fingers.
3) Insert the new ink cartridge into the machine (make sure that the
tab is facing out).
4) Replace the ADF exit tray.
9. Installing the Dual Line Kit (FO-60DL)
Note: The FO-60DL Dual Line Kit cannot be installed if the FO-NP1
Network Printer Kit is installed.
Important! The following procedure is to be performed only by a qual-
ified service technician. Be sure to turn off the power, unplug the
power cord, and unplug the telephone line before proceeding. In addi-
tion, touch a grounded piece of metal to discharge any static electricity
that may be on your body. Make sure that an extension phone is not
connected to the machine.
1) Press the cover release to open the print compartment cover.
2) Remove 6 screws from the rear cover.
(Remember which screw secures the small cover on the left side of
the rear cover, as it must be replaced in the same position).
Remove the small cover, and then remove the screw underneath.
Remove the rear cover.
3) Remove 6 screws and then remove the metal plate.
4) Remove the screw that holds the small side plate to metal plate
that was removed Step 3. Slide the small side plate up and remove
it from the metal plate. (Note: The small side plate is not no longer
needed, however, the screw is used again in “b” of Step 5.)
1
3
2

FO-DC635U
1 – 13
5) a: Attach the LIU board to the metal plate, positioning the modular
jacks as shown. The bottom edge of the board should fit into the
slots indicated by the arrows. Secure the LIU board with two of the
6 mm screws.
b: Attach the provided metal side plate.
6) Replace the metal plate and secure with screws in the order
shown.
7) Attach the dual line control board.
a: Insert the bushing into the hole in the dual line control board from
the outer side and secure it with the collar on the inner side.
b: Insert the winged end of the pin spacers into the metal plate, with
wings extended out vertically.
c: Attach the board so that the connector inserts into the connector
in the metal plate. Make sure that the pin spacers go into the holes
in the board. Secure the board with the 18 mm screw (which goes
into the bushing) and the remaining 6 mm screw. Tighten the
screws in the order shown.
8) Fasten the band to the core as shown and cut off the excess end.
Insert the cable through the core and wind it around the core twice.
9) Connect the cable to the LIU board and the dual line control board.
Secure the core band with the 10 mm screw.
10)Replace the rear cover.
(Be sure to replace the screw that secures the small cover in the
same position, as it is for plastic.)
11)Affix the “”LINE 2” label above the new jack.
a
b
1
2
3
4
b
a
c
1
2
For plastic
LINE 2

FO-DC635U
1 – 14
10. Installing the paper cassette option FO-CS2
(2nd)
Important! Be sure to turn off the power and unplug the power cord
before proceeding.
1) Remove the packing material and tape from the second paper cas-
sette.
2) Remove the covers from the sides of the first cassette (the cassette
already installed on the machine), using a flat-head screwdriver to
pry each of the catches at the bottom of the covers free (2 on the
right cover, 3 on the left cover).
3) Insert the green gear into the second cassette as shown. The side
of the gear that has the small secondary gear should face the
inside of the cassette, and should fit onto the metal shaft. Push the
gear in until the tab on the outer side goes into the slot on the metal
shaft. (Note: The gear is only used in the second cassette.)
4) Place the machine on top of the second cassette, and remove the
small cover from the rear of the first cassette. Connect the 10-pin
cable as shown, and insert it behind the guide indicated by the
white arrow.
5) Change the positions of the connectors on the circuit board of the
second cassette as shown (do not change the connectors on the
first cassette). Replace the small cover on the rear of the first cas-
sette, and attach the provided small cover on the rear of the second
cassette. (For the reconnection, see page 1-15.)
6) Attach the large support plate and then the small support plate to
the right side of the cassettes. Use 6 mm screws for the holes
marked with “A”, and 10 mm screws for the holes marked with “P”.
Secure the screws in the order indicated by the numbers.
7) Attach the support plate to the left side of the cassette. Use 6 mm
screws for holes marked with “A”, and 10 mm screws for holes
marked with “P”, securing the screws in the order indicated by the
numbers. (Note that the top hole on the right does not require a
screw.)
8) Attach the side covers to the first and second cassettes (refer to
steps 9 and 11 on the previous pages).
A2 A1
P3A3
A3
A4 P4
A4
2
1
A1
A3
A4
A2
P6 P5

FO-DC635U
1 – 15
11. Caution when installing paper cassette option FO-CS2(2nd) to FO-DC635
When installing the option FO-CS2 to FO-DC635U as a 2nd paper cassette, the short pins and cables on the paper cassette PWB must be recon-
nected.
+
-- -:@:H:9:N
Connect 1 pin and 2 pin
CAUTION
1st paper cassette (CN6)/2nd paper cassette (CN7) cable
From the Motor
From the Solenoid From the Paper
size sensor
From the
Cassette sensor
FO-DC635
FO-CS2
1st Paper Cassette
2nd Paper Cassette
Connecting position of each cable when
installing Paper Cassette Option FO-CS2(2nd)
to FO-DC635.

FO-DC635U
1 – 16
12. Quick reference guide
12.1. SENDING FAXES
Place your document (up to 50 letter-size pages) face down in the doc-
ument feeder.
(Note: For Normal Dialing and Direct Keypad Dialing, you can also
load the document after dialing the number.)
Press or if needed.
12.1.1 Normal Dialing
1) Lift extension phone or press .
2) Dial the fax number (if using an extension phone, dial on the exten-
sion phone keypad).
3) Wait for the reception tone (if a person answers, ask them to press
their Start key).
4) Press .
12.1.2 Rapid Key Dialing
1) Press the desired Rapid Key.
12.1.3 Speed Dialing
1) Press and enter the desired Speed Dial number (press
if you entered a 3-digits number).
2) Press .
12.1.4 Direct Keypad Dialing
1) Dial the fax number.
2) Press .
12.2. STORING AUTO DIAL NUMBERS
1) Press and then or until ENTRY MODE is
selected in the display.
2) Press . Make sure that DESTINATION SETTING is
selected.
3) Press . Make sure that SET is selected. (To clear a num-
ber, select CLEAR.)
4) Press .
5) To store a Rapid Key number, press the desired Rapid Key.
To store a Speed Dial number, press and enter a number
from 1 to 200 (press if you entered a 3-digits).
(If clearing a number, select it as explained above and then press
and .)
6) If the network scanner option is installed, SELECT DESTINATION
TYPE will appear. Make sure that FAX is selected and press
.
7) Enter the full fax number and press .
8) Enter a name by pressing the letter keys and press .
9) Select YES if this is a Chain Dial number or NO if not, and press
.
10)If the dual-line option is installed, select LINE-1, LINE-2, or AUTO
and press .
11)Press repeatedly to exit.
RESOLUTION
CONTRAST
SPEAKER
START/
ENTER
SPEED DIAL
START/
ENTER
START/
ENTER
START/
ENTER
MENU
START/
ENTER
START/
ENTER
START/
ENTER
SPEED DIAL
START/
ENTER
START/
ENTER
STOP
START/
ENTER
START/
ENTER
START/
ENTER
START/
ENTER
START/
ENTER
STOP

FO-DC635U
2 – 1
FO-DC635U Service Manual
CHAPTER 2. ADJUSTMENTS
[1] Adjustments
General
Since the following adjustments and settings are provided for this
model, make adjustments and/or setup as necessary.
1. Adjustments
Adjustments of output voltage (FACTORY ONLY)
1. Install the power supply unit in the machine.
2. Set the recording paper and document.
3. When the document is loaded, power is supplied to the output
lines. Confirm that outputs are within the limits below.
Output voltage settings
POWER
SUPPLY
PWB
CONTROL PWB
PRINTER PWB
HIGH VOLTAGE
PWB
CN5 CN1
CNPW1 CNPRT1
1
112 130
CN1
130
12
CN1
VR51
[DO NOT TOUCH!]
1
10
CN7 CN4
1
8
1
10
1
8
Fig. 1
Output Voltage limits Note
+5V MAIN 4.947V~5.25V CN5 7pin ↔8pin
+24V SUB 23.04V~24.96V CN5 1pin ↔2pin
Connector CN4
No.
Pin No. CN1
111+5V
210CHLREM
3TVR
4TMONV
5TMONI
6BVR
7VREM
8 C MON
9MG
10 2 +24V
Connector CN1
No.
Pin No. CN7
1 +24V MAIN
2MG
3DG
4DG
5 +5V MAIN
6 +5V MAIN
7 HEATER ON
8 H-RELAY OFF
Connector CN5
No.
Pin No. CNPW1
1 +24V SUB
2MG
3MG
4MG
5 +24V MAIN
6 +24V MAIN
7 +5V MAIN
8DG
9DG
10 DG
11 +5V MAIN
12 +5V MAIN
9
8
7
6
5
4
3