Hp D640 Users Manual

2015-02-09

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HP 5000
Cut Sheet
Printers

User Manual
Model D640
(Printer and Accessories)

HP 5000
D640 Cut Sheet Printer
User Manual
(Printer and Accessories)
Hewlett-Packard Company
C5620-90024
E0397

Notice
Hewlett-Packard makes no warranty of any kind with regard to this material, including, but not
limited to, the implied warranties of merchantability and fitness for a particular purpose.
Hewlett-Packard shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material.
Hewlett-Packard assumes no responsibility for the use or reliability of its software on equipment that is not furnished by Hewlett-Packard.
This document contains proprietary information which is protected by copyright. All rights are
reserved. No part of this document may be photocopied, reproduced, or translated to another
language without the prior written consent of Hewlett-Packard Company. The information
contained in this document is subject to change without notice.

Printing History
The dates on the title page change only when a new edition is published.
Edition 2.0. . . . . . . . . . . . . . .March 1997
Copyright ©1997 Hewlett-Packard Company
All rights reserved.
March 1997
Please address any comments or questions to:
Publications Manager
System Peripherals Operation
HP5000 Printers - MS 44MC
Hewlett-Packard Company
19111 Pruneridge Avenue
Cupertino, CA 95014

Copyrights and Trademark Credits
Adobe™, PostScript™, PostScript II and the PostScript Logo™ are trademarks of Adobe Systems Incorporated which may be registered in certain jurisdictions.
Arial, Times New Roman, and Monotype are registered trademarks of the Monotype Corporation.
Bi-Tronics™, PCL5™, and REt™ are trademarks of Hewlett-Packard Company.
Helvetica and Univers are trademarks of Linotype AG and/or its subsidiaries in the U.S. or
other countries.
Macintosh computer is a product of Apple Computer, Inc.
Microsoft® is a U.S. registered trademark of Microsoft Corporation; Windows™ and LAN
Manager™ are trademarks of Microsoft Corporation.
Novell™ is a trademark of Novell, Incorporated.
TrueType™ is a trademark of Apple Computer, Inc.
WordPerfect is a registered trademark of WordPerfect Corporation.
ITC Zapf Dingbats is a U.S. registered trademark of International Typeface Corporation.
Albertus, Antique Olive, Arial, CG Omega, CG Times, Clarendon Condensed, Coronet, Courier, Garamond, Letter Gothic, Marigold, Symbol, Times New Roman, Univers, Univers Condensed, Wingdings are trademarks of Agfa Division of Miles Inc.
CG Times, a product of Agfa Corporation, is based on Times New Roman, a registered trademark of Monotype Corporation PLC.
Centronics is a trademark of Centronics Data Computer Corp.
Intellifont is a trademark of Miles Inc.
Portions of the software in the PostScript upgrade are Copyright© 1990-1997 Pipeline Associates, Inc.
Other product names mentioned in this manual may also be trademarks and are used here for
identification only.

iii

Caution and Warnings
A Caution denotes a hazard. It calls attention to a procedure which, if done incorrectly or inattentively, could damage or destroy part or all of the product. Do not proceed beyond a Caution
until the indicated conditions are fully understood and met.
A WARNING denotes a hazard. It calls attention to a procedure or practice, which, if not done
correctly or adhered to, could result in personal injury. Do not proceed beyond a WARNING
sign until the indicated conditions are fully understood and met.

Manual Conventions
The following conventions are used in this manual:
Note

Notes contain important information set off from the text.

Caution Caution messages indicate procedures which, if not observed, could result in
damage to equipment.

WARNING!
injury.

Warning messages call attention to situations that could result in personal

Printer Warning Symbols
In addition, the following Warning symbols appear on the printer:
WARNING! This symbol indicates high voltage is present. Do not remove or open any
panel marked with this symbol.

WARNING HOT! This symbol indicates high temperatures may be present that could result
in burns or other high-temperature hazards.

WARNING! Disconnect the printer from its power source whenever performing any
maintenance or installation procedure.
The printer is equipped with safety interlock switches on most of its covers. The switches disable parts of the printer when the covers are opened. These areas present the risk of electric
shock, burns, and injury from mechanical hazards.
Any unauthorized removal of safety covers, manipulation of safety switches, and interference
with the safety system is strictly prohibited. Such actions can cause personal injury and can
damage the system. Also make sure that the operating and maintenance areas are not
obstructed in any way.
With any drive mechanism, loosely hanging items of clothing and jewelry, such as ties, belt
ends, necklaces, bracelets, and rings, and unprotected hair can cause injury if caught in the
mechanism.

Preface
The User Manual contains all the information needed to operate the printer.
This information is directed toward printer operators who are familiar with basic printer operations and comfortable with replacing printer consumables such as the toner.
We suggest you take the time to look through and familiarize yourself with the various chapters of the D640 User Manual.
Chapter 1, "About Your Printer", provides an overview of the printer’s features.
Chapter 2, "Control Panel", is a detailed reference to all of the printer’s options.
Chapter 3, "Printer Tasks", explains how to set up printing options.
Chapter 4, "Ordering and Replacing Consumables", guides you through replacing printer consumables, such as toner and developer, and explains how to order more consumables.
Chapter 5, "Maintenance", guides you through cleaning and other maintenance procedures that
keep print quality at its best.
Chapter 6, "Advanced Topics", explains additional topics about the printer that may be of
interest to you. Topics include how to obtain optimal print quality, manage consumables,
adjust paper path alignment, and so on.
Appendix A, "Printer Messages" is a complete list of printer messages, which tell you when to
replace consumables or notify you of problems, and provides samples of simulated poor print
quality to help you diagnose print quality problems.
Appendix B, "Host Serial and Parallel Interface Configuration" describes the serial and parallel
connection options between the printer and its host, and tells you how to configure them.
Appendix C, "Specifications and Regulatory Information", provides specifications for the
printer, HCI, and HCO, and all applicable safety and regulatory compliance statements.
Appendix D, "Using Paper", provides information about paper and other media used with the
printer.
Appendix E, "Printing Reports", tells you how to print informational reports about printer settings and installed options.
Appendix F, "Warranty and Support", tells you how to obtain assistance in setting up the D640
printer and repairing it.
Please feel free to send us your comments, complaints, or suggestions by filling out the reader
response card at the end of this manual.

Other Manuals
The HP 5000 D640 Installation Manual, C5620-90015 (English version) guides you through
unpacking, setup, testing, and configuration of your printer.
The HP 5000 D640 Technical Reference Manual, C5620-90000, is a guide to using fonts and
the PCL and PJL emulations on the D640. It also documents additional aspects of printer usage
in detail.
The HP 5000 D640 Service Manual, C5620-90013, is a comprehensive technical reference to
all mechanical and electronic components in the printer. The Service Manual helps you perform fault diagnosis and isolation, then guides you through replacement of subassemblies.
The PCL/PJL Technical Library, 5021-0330, which contains:
The PCL Comparison Guide, 5010-3998
The PJL Technical Reference Manual, 5010-3999
The PCL5 Printer Language Technical Reference Manual, 5961-0509

vii

Table of Contents

About Your Printer
Standard Features of the D640 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Accessories For the D640 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Full 600 x 600 Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Rugged Construction for Long Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Consumable Replacement and Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Duplex Printing With No Performance Degradation . . . . . . . . . . . . . . . . . . 1-2
Toner Recycling and Economy Mode Printing . . . . . . . . . . . . . . . . . . . . . . 1-3
High Capacity Paper Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Custom Paper Size Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Backlit LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Multiple Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
PostScript Level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Compatibility with LaserJet 4Si/5Si Printer . . . . . . . . . . . . . . . . . . . . . . . . 1-4
PCL Level 5e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Integral Hard Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Energy Star Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Getting to Know the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
The D640 Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Front and Right Side of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Behind the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Behind the Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Behind the Upper Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Rear and Left Side of the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
High Capacity Input Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
High Capacity Output Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Powering On the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Control Panel
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Getting to Know the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Control Panel Features and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Checking Printer Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Normal Printer Status (No Error Condition Displayed) . . . . . . . . . . . . . . . 2-3
Abnormal Printer Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Checking Paper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Function Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Navigating Through the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Custom Menu Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Printing Menu Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Configuration Menu Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
PCL Menu Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Comms Menu Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Serial Interface Configuration Example . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Maintenance Menu Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
PapSize Menu Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Test Menu Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Printer Tasks
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Removing and Installing the Paper Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Adjusting Standard Tray Paper Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Setting Standard Paper Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Adjusting Custom Tray Paper Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Setting Custom Paper Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Configuring Custom Tray Menu Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Loading Paper Into Trays and HCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Opening Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Locking Paper Trays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Stopping or Interrupting Print Jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Clearing a Paper Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Clearing Paper Input Jams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Clearing a Tray Pick Error Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Clearing a Feed Path Paper Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Clearing HCI Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Clearing HCI Jam 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Clearing HCI Jam 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Clearing Paper Path Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Clearing a Fuser Unit Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Clearing a Duplex Unit Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Clearing a Reversing Unit Area Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Clearing Paper Output Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Clearing an Ejection Unit Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Clearing an HCO Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Handling Error Messages and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 3-49
Error Reporting/Action Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Ordering and Replacing Consumables
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Overview of Consumable Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Ordering D640 Printer Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Replacing Toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Replacing the Toner Collector Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Replacing the Cleaning Roller (When Indicated on Control Panel) . . . . . . 4-7
Replacing Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Discharging Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Adding New Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Installing Developer Collector Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Replacing the Ozone Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Drum Kit - Replacing Drum and Transfer Assembly . . . . . . . . . . . . . . . . . . . 4-18
Setting Up the Printer for Drum Kit Replacement . . . . . . . . . . . . . . . . . . . 4-18
Removing the Transfer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Removing the Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Unpacking the New Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Installing the Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Installing the New Transfer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Fuser Kit - Replacing the Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer Pick Roller Kit - Replacing the Tray Pick Rollers . . . . . . . . . . . . . . .
At the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Printer Pick Rollers (Upper and Lower) . . . . . . . . . . . . . .
New Printer Pick Roller Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Printer Lower Pick Rollers . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Printer Upper Pick Rollers . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Covers and Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HCI Pick Roller Kit - Replacing the HCI Pick Rollers . . . . . . . . . . . . . . . . .
At the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the HCI Pick Rollers (Upper and Lower) . . . . . . . . . . . . . . . .
New HCI Pick Roller Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the HCI Lower Pick Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-29
4-30
4-31
4-33
4-33
4-33
4-37
4-37
4-39
4-41
4-42
4-42
4-42
4-46
4-49

Maintenance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Weekly Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Removing Stray Toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Precharger Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Paper Feed Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Paper Input Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Printer Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Periodic Cleaning (When Replacing Drum). . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Reversing Unit Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Duplex Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Transfer Assembly - Transfer LED Areas . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Transfer Assembly Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
LED Array Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Reinstalling the Transfer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

xii

Advanced Topics
Maintaining Print Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Print Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Good Quality Print Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Specific Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Managing Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Toner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Drum and Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Ozone Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Transfer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Pushing Consumable Life Beyond Estimated Yields . . . . . . . . . . . . . . . . 6-11
Adjusting Paper Path Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Printing Alignment Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Measuring Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Setting Alignment Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Setting Up Edge-to-Edge Printing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Configuring for LaserJet IIIsi and 4si Compatibility . . . . . . . . . . . . . . . . . . . 6-24
Paper Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Example Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Using the LaserJet 5Si Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Using Virtual Font Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

A Printer Messages
Printer Initialization Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Printer Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Printer Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Status Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Paper Jam Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Call Engineer Error Messages and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8

xiii

B Host Serial and Parallel Interface Configuration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Using the Serial Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Using the Parallel Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

C Specifications and Regulatory Information
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Printer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Best Printing Area Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
D640 Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
High Capacity Input (HCI) Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
HCI Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
High Capacity Output (HCO) Specifications . . . . . . . . . . . . . . . . . . . . . . . . . C-10
HCO Paper Handling Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10
HCO Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-11
HCO Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-11
HCO Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
Printer Custom Paper Tray Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
PostScript Upgrade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
Safety and Regulatory Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13
FCC Statement (USA only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13
DOC Statement (Canada only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13
Europe RFI Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13
Acoustics Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14
Data Communications (United Kingdom only) . . . . . . . . . . . . . . . . . . . . C-14
Material Safety Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14
EPA Energy Star Computer Compliance . . . . . . . . . . . . . . . . . . . . . . . . . C-15
Safety Standards and General Considerations . . . . . . . . . . . . . . . . . . . . . . . . C-15
Laser Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-16
Printer Laser Equipment Compliance Label . . . . . . . . . . . . . . . . . . . . . . . C-16
Laser Safety Statement (USA Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-16
Laser Safety Statement (Finland Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . C-17
HP Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-18

xiv

D Using Paper
Supported Print Media Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Alternate Sources of Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Paper Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Sources of Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Media Selection Specifications and Guidelines . . . . . . . . . . . . . . . . . . . . . . . .D-3
Recommendations to the Customer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Potential Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7
Fusing Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8
Understanding Paper Ream Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-9
General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-9
Recommended Paper Specification Summary . . . . . . . . . . . . . . . . . . . . . .D-10
Pre-printed Forms and Letterhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-11
Adhesive Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-12
Other Special Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-16
Things to Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-16
Purchasing, Handling, and Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-16
Purchasing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-17
Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-17
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-18
Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-18
Printer Normal Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . .D-19
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-20
Evaluate Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-23

E Printing Reports
The Printer Setup Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Setup Report, Page 1 Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
Setup Report, Page 2 Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
The Maintenance Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Maintenance Report Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
The Typeface Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
Typeface Report Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
The Symbol Set Table Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10
Symbol Set Table Report Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10

The Printer Menu Settings Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-12
Printer Menu Settings Report Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-12
The Ripple Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-16
Troubleshooting with the Ripple Test Pattern . . . . . . . . . . . . . . . . . . . . . E-16

F Warranty and Support
Where To Call For Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
For installation and general printer questions, call: . . . . . . . . . . . . . . . . . .
For hardware problems, call: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HP Maintenance Agreements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HP5000 Model D640 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

xvi

F-1
F-1
F-2
F-6
F-6
F-6

About Your Printer

Figure 1-1

D640 with High Capacity Input and High Capacity Output installed

Standard Features of the D640 Printer
•
•
•
•
•
•
•
•
•

600 x 600 dpi resolution
40 page per minute printing (simplex)
Duplex printing from A5 to Ledger size paper, plus custom sizes
Prints forms, pre-punched, labels, and transparency media
Standard paper input capacity of 1500 sheets (three paper trays)
16 MB of memory, expandable to 64 MB
Hewlett-Packard LaserJet printer compatibility
EconoMode for reducing toner expense
Microfine toner

About Your Printer

1-1

About Your
Printer

Accessories For the D640 Printer

• Toner recycling
• Virtual Font Cartridges resident on internal hard disk
• Operator-replaceable consumables (toner, developer powder, drum, fuser, and paper pick
rollers)
• Bitronics parallel and serial interfaces with automatic switching
• PCL 5e, PJL, and HP-GL/2 language support built in
• IEEE 1284C support for 10 meter parallel cables
• Energy Star compliance

Accessories For the D640 Printer
•
•
•
•
•

High-Capacity Input (HCI) holds 3000 sheets
High Capacity Output (HCO) holds 2000 sheets
Custom-size paper trays
PostScriptTM Level 2
16 MB memory upgrade

Full 600 x 600 Resolution
The D640 provides full 600 X 600 dpi (dots per inch) laser resolution, and microfine toner,
ensures output with a professional and crisp look.

Rugged Construction for Long Life
The HP 5000 D640 is ruggedly constructed for years of printing at the rated monthly duty
cycle and for continuous operation without danger of damage to the print engine, a capability
especially important for peak printing periods such as month-end processing.

Consumable Replacement and Tracking
D640 toner and developer are easily replenished from bottles, and all consumable printing
components (photoconductor drum, fuser, and paper pick roller) are replaceable without tools.
To further simplify operation and management, the D640 tracks toner, developer,
photoconductor drum, fuser, and paper pick roller usage and displays operator messages
advising replacement as needed.

Duplex Printing With No Performance Degradation
The D640 performs duplex printing (letter and A4 paper sizes) at 40 page sides per minute.

1-2

About Your Printer

Toner Recycling and Economy Mode Printing
The D640 supports both toner recycling and economy printing mode for greater toner yields.
Toner recycling can increase toner yield by up to 20%. In economy mode, toner usage is
reduced by up to 30% with minimal impact on text print quality.

High Capacity Paper Handling
The D640 features a maximum standard input capacity of 1500 sheets in three 500-sheet paper
trays. Maximum standard output capacity is 400 sheets. Addition of the High Capacity Input
(HCI) accessory increases the total input capacity to 4500 sheets. The High Capacity Output
(HCO) accessory handles up to 2000 sheets and supports output jogging for job separation.

Custom Paper Size Support
The D640 supports non-standard paper sizes with a custom paper tray. Paper sizes as small as
4.75 inches by 7.2 inches (120 mm x 182 mm) or as large as 11.7 inches by 17 inches (297 mm
x 431.8 mm) can be accommodated. The custom paper tray can be used as tray1, tray2, or
tray3. When using more than one custom paper tray, each tray must contain the same size of
paper.

Backlit LCD Display
The D640 features a backlit, menu-oriented, Liquid Crystal Display for ease of configuration
and printer management. Five different languages are supported (English, German, French,
Spanish, and Italian).

Multiple Interfaces
The D640 features integrated Bitronics (parallel) and serial interfaces and supports automatic
switching between these two interfaces. HP JetDirect EX external network interfaces
(purchased separately) provide Ethernet/IEEE 802.3 or Token Ring IEEE 802.5 LAN
interfaces. The same network management software used with HP LaserJet printers and HP
JetDirect cards can be used with the D640 and HP JetDirect EX products, allowing networked
HP printers to be administered and managed with a common set of software tools.

PostScript Level 2
PostScript is available for the D640 as an add-on product and includes an additional 16
megabytes of memory. The printer can be configured to automatically switch between
PostScript and PCL print jobs.

About Your Printer

1-3

About Your
Printer

Accessories For the D640 Printer

Compatibility with LaserJet 4Si/5Si Printer
The HP 5000 D640 is compatible with the HP LaserJet 4Si printer driver. However, because
the D640 provides more functionality than the HP LaserJet 4Si, not all D640 features can be
accessed with the 4Si printer driver. You can use third party products or additional
programming to access additional D640 features.
The HP 5000 D640 is also compatible with the HP LaserJet 5Si printer driver. However, there
are a few limitations when using the LaserJet 5Si printer driver. Please refer to Chapter 6,
"Advanced Topics", for a discussion of LaserJet compatibility.

PCL Level 5e
The D640 printer supports PCL, the print language of HP LaserJet printers and the most
widely installed print language in the world. Support for PCL Level 5e provides powerful
formatting capabilities and compatibility with a wide range of software solutions.

Integral Hard Disk
The D640 features an internal hard disk drive(850 MB or more) factory preloaded with
thousands of fonts and symbol sets. The hard disk can also be used for storing additional fonts,
electronic forms as PCL macros, and company logos.

Energy Star Compliance
To help minimize power consumption, the D640 complies with the Energy Star Program of the
U.S. Environmental Protection Agency.
Note If you have not done so, please refer to the Installation Manual and complete the
installation procedures. These procedures ensure the safe operation of the printer and the best
print quality.
The printer requires regular maintenance, as described later in this manual. Although
maintenance takes only a few minutes weekly, it is very important to the quality of the
printouts and the life of the printer.

Caution Hewlett-Packard recommends the use of Hewlett-Packard labelled consumable
supplies. Hewlett-Packard is not responsible for any failures or print quality issues arising
from the use of other than Hewlett-Packard supplies. Such failures are not covered under
warranty or by any Hewlett-Packard service agreement.

1-4

About Your Printer

Getting to Know the Printer
Orientation
Unless otherwise noted, all instructions in this manual assume you are facing the front of the
printer, with the paper trays on the bottom and the paper output on the top.

LTR

HCO

D640

HCI

Printer
Figure 1-2

D640 with High Capacity Input and High Capacity Output

About Your Printer

1-5

About Your
Printer

Getting to Know the Printer

The D640 Printer
Your printer may or may not be installed with the optional high capacity input (HCI) and high
capacity output (HCO) accessories. Figure 1-2 shows the printer, the HCI, and the HCO
installed together. If you want to know more about these optional accessories, refer to “High
Capacity Input Accessory” on page 1-16 for the HCI, or “High Capacity Output Accessory”
on page 1-17 for the HCO.
Figure 1-3 shows the front and right sides of the printer and an overview of the Control Panel.
LCD Panel Power Save Mode Indicator

.. .
... .. .... ... ..
.

*Speaker

Control panel
Function buttons
Screen contrast control
Standby switch

Ejection unit
Paper output tray
Front cover

....

Front door
Upper right cover
Tray1
Tray2
Tray3
Lower right cover
Paper size indicators
Paper level indicators
Main power switch
* Not used

Figure 1-3

1-6

Front and right side of the printer

About Your Printer

Front and Right Side of the Printer
In Figure 1-3, starting at the Control Panel at the top left and reading clockwise, refer to the
following points of interest.
• Control Panel: Consists of function buttons and a liquid crystal display (also referred to
as the LCD panel) that presents messages about printer activity.
• Screen contrast control: Allows you to adjust the contrast of the display.
• Ejection unit: Deposits paper to the output tray.
• Standby switch: Powers the printer on and off.
• Output tray: Holds printed pages.
• Upper right cover: Provides access to add toner and developer.
• Lower right cover: Provides access to the paper path (for jam clearing) from the paper
trays.
• Paper indicators: Provide a visual gauge for the size and relative amount of paper in each
tray.
• Main power switch: Applies line voltage to the printer.
• Trays 1, 2, and 3: These are the input paper trays for standard size media. You can also
obtain and install optional adjustable custom trays that hold custom (or standard) sizes of
paper.
• Front door: Provides access to the printer’s interior.
• Front cover: Provides access to the printer’s floppy disk drive for installing PostScript
and PCL code updates.

About Your Printer

1-7

About Your
Printer

Getting to Know the Printer

PC card slot *
..........
......

Serial diagnostic port *
Floppy disk drive

Front cover

* For support use only.

Figure 1-4

1-8

Behind the front cover

About Your Printer

Behind the Front Cover
The front cover is located below the Control Panel, as shown in Figure 1-4. When you open it,
you find the following:
• PC card slot: Used only for support testing, and covered with a rubber protective cap.
• Serial diagnostic port: Used only for testing.
• Floppy disk drive: Used for updating printer functions and installing the PostScript
upgrade.

About Your Printer

1-9

About Your
Printer

Getting to Know the Printer

.....
......
....

Fuser locking knob
Fuser unit
Drum unit locking knob

Precharger cleaner
Drum unit

Cleaning roller
Lever 5
Decurler roller
knob

Lever b1
Knob 2

Decurler lever
Lever 4

Knob 1

Duplex unit
Duplex roller knob

Handle 3
Lever 6
Transfer assembly guide

Figure 1-5

Behind the front door

1-10 About Your Printer

LTR

Behind the Front Door
When you open the front door of the printer, you see the printer’s internal components, shown
in Figure 1-5 and described below.
• Fuser: Applies heat and pressure, which melts the toner and adheres it to the paper.
• Drum unit: Contains the precharger, photoconductor drum, and cleaner.
• Transfer guide: Contains the transfer unit, which moves the print image from the drum to
the paper.
• Fuser Locking knob: Secures the fuser in the printer chassis.
• Cleaning roller: Applies silicone oil and cleans the fuser roller.
• Drum unit locking knob: Secures the drum.
• Precharger Cleaner: Helps keep the drum surface free of stray toner.
• Decurler roller knob: Used to clear paper jams in the immediate area.
• Duplex roller knob: Used to clear paper jams in the duplex paper path (during doublesided printing).
• Knob 1: Used to clear paper jams as the paper exits the paper trays and enters the drum
area.
• Knob 2: Used to clear paper jams as the paper exits the paper trays and enters the drum
area.
• Handle 3: Lowers the transfer guide to clear paper jams in the drum area.
• Decurler lever: Provides access to paper in the decurler area to clear paper jams.
• Lever b1: Secures the internal printing components in the paper path.
• Lever 4: Releases tension on paper in the fuser area to clear paper jams.
• Lever 5: Provides access to paper in the reverser area to clear paper jams.
• Lever 6: Provides access to paper in the duplexer area to clear paper jams.

About Your Printer 1-11

About Your
Printer

Getting to Know the Printer

Install toner here
Install developer here

........
......
..

Toner collector bottle
Developer collector bottle

Toner hopper
Developer unit
Upper right cover

Figure 1-6

Behind the upper right cover

1-12 About Your Printer

Behind the Upper Right Cover
By opening the upper right cover, you gain access to the printer’s consumables, as shown in
Figure 1-6 and described below.
• Toner hopper: A reservoir that holds toner. The Control Panel displays messages to
indicate toner low and toner empty status. Never add toner before the printer indicates that
toner is needed.
• Developer unit: holds the developer mixture that prepares toner for transfer to the
photoconductor drum.
• Developer collector bottle: Collects used developer for disposal.
• Toner collector bottle: Collects waste toner for disposal.
Note Never pour waste toner into the toner hopper. If you do not want to discard waste
toner, use the toner recycling feature described in “Toner Recycling Switch” on page 6-8.

Caution Never re-use developer. Severe print quality problems and physical damage may
occur if you do so.

About Your Printer 1-13

About Your
Printer

Getting to Know the Printer

Serial port (RS232/422)

Switches used for support only
Ejection unit
Parallel port
(IEEE 1284C)

Upper left cover
Paper side exit
(under cover)

User documentation
holder
Ozone filter
HCO attachment
points (under covers)

HCI connector
AC input
power connector
HCO connector
Lower connector
not used

Figure 1-7

Rear and left side of the printer

1-14 About Your Printer

Rear and Left Side of the Printer
The rear of the printer has the features shown in Figure 1-7 and described below.
•
•
•
•
•
•
•
•
•

Ozone filter: Absorbs and reduces the printer’s ozone emissions.
Documentation holder: Provides a convenient location to store the printer manuals.
Parallel port: Supports IEEE 1284C bidirectional host interconnections.
Serial port: Supports RS232/422 host interconnections.
Ejection unit: Provides access to clear paper jams in this area.
Paper Side Exit (under cover): Provides access to the external paper path opening.
HCO connector: Used to control the optional HCO stacker.
Lower connector: Reserved for future accessories.
AC input power connector: Accepts either 120-127 or 200-240 VAC input power (fuser
must be matched to the input voltage).
• HCI connector: Used to control the optional HCI feeder.

About Your Printer 1-15

About Your
Printer

Getting to Know the Printer

High Capacity Input Accessory
An optional High Capacity Input (HCI) accessory (shown in Figure 1-8) is available to provide
an additional input capacity of 3000 sheets. The HCI sits on rails attached to the printer and is
electrically connected to the printer by a cable, and obtains its power from the printer. The HCI
highlights are:
• HCI release handle: When squeezed, detaches the HCI from the printer.
• Paper table lowering button: When pressed, lowers the table for paper replenishment.
The printer must be powered on with all covers closed, or the table will not lower.
• HCI door: Allows visual inspection of the paper supply.
• Door handle: Provides easy access to the paper supply.
• Elevator-type movable table: Supports the paper supply.

HCI release handle
Paper table lowering button
HCI door
Door handle

Printer

Figure 1-8

Paper table
(inside door)

High Capacity Input accessory

Note The HCI is pre-set for either A4 or Letter paper sizes. (Adjusting between the two
sizes should be performed only by a trained service technician.)

1-16 About Your Printer

High Capacity Output Accessory
The D640 can stack paper onto the optional High-Capacity Output (HCO) accessory (shown in
Figure 1-9), which holds up to 2000 sheets. The HCO uses a standard power cord that may be
plugged into any standard 120VAC or 240VAC (depending on the HCO version) wall outlet.
The HCO is mechanically and electrically connected to the printer. Power is controlled by the
Main Power switch and is normally left in the ON position.

ON
OF

HCO Interface
control cable

Figure 1-9

Main Power Switch
Input power cord connector

High Capacity Output accessory

About Your Printer 1-17

About Your
Printer

Getting to Know the Printer

Powering On the Printer

Powering On the Printer
1.

Locate the main power switch and standby switch as shown in Figure 1-10.

ON
............

Standby switch
ON

OFF
Main power switch

Figure 1-10 Standby switch and Main power switch

2.
3.

Turn on the Main power switch by pressing in at the top of the switch.
Turn on the Standby switch, as shown in Figure 1-11, by holding the switch in the up
position momentarily.
Screen contrast control
MODEL

5000

Standby switch

D640

...
. .. .. . ..
. .. .
.. .
ON

Figure 1-11 Turning on the standby switch

If you do not see anything on the display after 5 to 10 seconds, turn the screen contrast
control to the 2:00 o’clock (1400) position, as shown in Figure 1-11. You can then adjust
the control to an appropriate level.

1-18 About Your Printer

2
Introduction
The D640 printer performs many kinds of printing tasks. Through the Control Panel menus,
you can select options and features.
If your print job contains commands that change the Control Panel settings, the print job
commands will be effective for that job only.
This chapter is a detailed reference for all of the D640’s menu settings:
If you want to
•
•
•
•
•
•
•
•
•
•
•

Understand Control Panel functions
Check the printer’s status
Check the printer’s paper
Select Custom menu settings
Select Printer menu settings
Select Configurations menu settings
Select PCL menu settings
Select Comms menu settings
Select Maintenance menu settings
Select PapSize menu settings
Select Test menu settings

Go to:
page 2-2
page 2-3
page 2-5
page 2-9
page 2-11
page 2-14
page 2-19
page 2-21
page 2-24
page 2-26
page 2-28

Control Panel

2-1

Control Panel

Getting to Know the Control Panel

Getting to Know the Control Panel
LCD panel
PowerSave indicator
Standby switch

..
. ... .. . ..
. .. .
.. .
ON

Speaker
(not used)
Function buttons
Screen contrast control

Figure 2-1

Control Panel

Control Panel Features and Functions
The Control Panel is one of the means to control and configure the printer. Through the
Control Panel, the printer displays information about aspects of normal operation, paper jams,
consumable status, and error conditions. Use the function buttons on the Control Panel to
change printer settings.
Control Panel features include:
• The Standby switch turns the printer on and off:
- When you move the Standby switch momentarily to the ON (or up) position, the printer
powers on. There will be up to a 2 minute delay before you can print while the printer
performs an initialization sequence and warms the fuser to operating temperature.
- When you move the Standby switch momentarily to the OFF (or down) position, the
printer is powered off and placed in Standby mode. There may be a delay in the printer
powering off; any pages currently moving through the paper path are printed before the
printer powers off.
• The Screen contrast control adjusts the contrast of the LCD panel.
• The Function buttons are located below the LCD panel. These five buttons perform
different functions during printer operations, such as when the printer is printing, or when
you are changing settings. Figure 2-6 shows these function buttons.

2-2

Control Panel

At any given time, you can only perform the action shown on the Control Panel for a
particular button. If a button is undefined, it performs no function.
• The Speaker is not currently activated.
• The Liquid crystal display (LCD) panel displays printer status and operating information.
Figure 2-6 shows the basic menu screen, called the Main Screen. Messages on the Main
Screen:
- Show information about printer status, progress of the print job, and the current paper
path.
- Display the paper size configured for each input source.
- Show any paper jams in the paper path line.
• The PowerSave indicator, when on, indicates that the printer is in PowerSave mode. The
backlight of the LCD panel also turns off in PowerSave mode.

Checking Printer Status
You may want to check the D640’s status for many reasons:
• To verify that it is ready for printing.
• To verify that it is either Online or Offline.
• To check that the correct date, time, and printing protocol are set.

Normal Printer Status (No Error Condition Displayed)
The message field of the display shown in Figure 2-2 reports the D640’s status.

Ready - - free
JUN 18 05:32.23
PCL

Message field

Printer is offline

Offline
Online
Offline

Figure 2-2

600dpi

Custom

Test

LTR
LTR
LTR
PapSize

Printer status

The message field information indicates:
• Ready -- free
The printer is ready to print.
• JUN 18 05:32.23
Displays the current date (JUN 18) and time (05:32.23).

Control Panel

2-3

Control Panel

Checking Printer Status

• PCL
Indicates that the printer is using PCL (Printer Control Language) emulation.
• Online
The printer is ready to print.

Abnormal Printer Status
The message field (the first and second line) of the Control Panel reports the printer’s
conditions, such as low toner, paper jam, or door open. In these cases, the Control Panel also
describes what action is needed to remedy the situation. Serious conditions may require a
service call. Error messages are listed in Appendix A.
The printer constantly monitors the state of consumables such as developer and toner. When a
consumable runs low, or has reached its end-of-life, a message notifying you to replace the
consumable appears on the Control Panel. An example of such a report is shown in Figure 2-3.

Toner empty
Add New Toner
PCL
Offline
Offline
Clear
Figure 2-3

Test

LTR
LTR
LTR
PapSize

Toner empty indication

The printer detects when a cover is open and stops printing to protect you from electrical and
mechanical hazards. If a cover is open, the printer reports the condition, like the screen shown
in Figure 2-4.
Note

Do not open a cover while the printer is printing; this will cause a paper jam.

Ejection unit cover open
Close ejection unit cover
PCL
Online
Offline
Clear
Figure 2-4

2-4

Custom
Problem status report

Control Panel

Test

LTR
LTR
LTR
PapSize

Checking Paper

Checking Paper
Check the Control Panel to make sure that paper is loaded properly and to observe the progress
of printing. You can:
• Verify that the paper trays contain paper.
• Verify that correct paper sizes are in the paper trays.
• Check on paper travel through the paper path when printing.

Control Panel

Figure 2-5 shows the paper supply and path information.
Current paper path

Ready - - free
JUN 18 05:32.23
PCL
Offline
Online
Offline
Figure 2-5

600dpi
LTR
LTR
LTR

Custom

Test

LTR
PapSize

Paper supply and path information

The Main Screen display (Figure 2-5) shows the path the paper takes from the selected paper
tray to the selected output area. The display also shows the installed paper trays and associated
paper sizes, as listed in Table 2-1.
Paper Size
Letter
(LTR)

A4
Legal
(LGL)
Custom
(CUS)

Symbol

Description
LTR indicates that the tray contains letter size paper. The symbol indicates
the long edge is leading into the paper path and the filled-in symbol
indicates the tray has paper. Note: paper size determines whether the long
or short edge leads into the paper path.
A4 indicates that the tray is set to contain A4 size paper. The empty
symbol indicates the tray has no paper.
LGL indicates legal size paper installed. The symbol indicates the short
edge is leading into the paper path and that the paper tray has paper.
CUS indicates that custom paper is installed in the custom tray. This
particular custom tray paper configuration has the long edge leading into
the paper path.

Control Panel

2-5

Function Buttons

HCI

HCI indicates that the HCI is installed and contains paper. Paper size can
only be LTR or A4 (depending on the model of the HCI).

A3 indicates that A3 size paper is the specified paper size, but the missing
symbol indicates that the tray is open.

Table 2-1 lists all available standard paper categories and their respective sizes.
Table 2-1

Standard paper sizes

Category

Dimensions

Letter

8.5 x 11 in (216 x 279 mm)

Legal

8.5 x 14 in (216 x 356 mm)

Ledger

11 x 17 in (280 x 432 mm)

Executive

7.25 x 10.5 in (184 x 267 mm)

11.69 x 16.53 in (297 x 420 mm)

8.26 x 11.69 in (210 x 297 mm)

5.84 x 8.26 in (149 x 210 mm)

B4 (JIS)

10.11 x 14.32 in (257 x 364 mm)

B5 (JIS)

7.16 x 10.11 in (182 x 257 mm)

* LGR note: Ledger paper extends across the entire tray bottom. When you install ledger paper, lift and
remove the left guide and store it in the molded pocket (located on front panel) labeled LGR.
JIS: Japan Industrial Standards Committee

Printer Tasks

3-3

Printer Tasks

Figure 3-3

Adjusting Standard Tray Paper Guides

7.16
5.84

8.26

10.11
10.5
11
11.7

14
14.32

16.53
17

Figure 3-4

3-4

(149 x 210mm)

(182 x 257mm)
(184 x 267mm) — 7.25 x 10.5 in.
(216 x 280mm) — 8.5 x 11 in.

8.26

7.25

10.11

8.5

11.69
11

JISB5
Executive
Letter

(210 x 297mm)

(216 x 356mm) — 8.5 x 14 in.
(257 x 364mm)

Legal
JISB4

(297 x 420mm)
280 x 432mm) — 11 x 17 in.

Paper Sizes quick reference

Printer Tasks

Ledger ("B" size)

Adjusting Standard Tray Paper Guides

Each paper guide has a blue locking thumbwheel, as shown in Figure 3-5.

Guides

(3) Locking devices

LTR

Paper guides

Turn the blue locking thumbwheels on each paper guide counterclockwise to the OPEN
position (Figure 3-6).

O SE
CL

LTR
LGR

O PEN

Figure 3-6

Locking device

Lift paper guides out of their current locations and place them in the new paper size locations.
The paper size indicators on the tray are visible through the round circle cutout on the paper
guide, as shown in Figure 3-7.

Printer Tasks

3-5

Printer Tasks

Figure 3-5

Adjusting Standard Tray Paper Guides

O SE
CL

O PEN

LTR
LGR
LT

LGL

Figure 3-7

3.
4.

Paper guide size selection

Adjust both paper guides for the same paper size.
Turn the blue locking thumbwheels on each paper guide clockwise to the CLOSE
position to secure it. (Figure 3-8).

O SE
CL

LTR
LGR

O PEN

Figure 3-8

3-6

Securing the paper guide

Printer Tasks

Setting Standard Paper Sizes

Setting Standard Paper Sizes
Use the PapSize setting to configure the printer for the size of paper installed in each paper
source.
Note The D640 does not detect paper size. You must visually check each drawer to verify
that it contains the correct paper.
1.

At the Main Screen, press PapSize. Figure 3-9 appears.

PapSize

tray1size
tray2size
tray3size

=LETTER
=LETTER
=LETTER

Online

Figure 3-9

2.
3.
4.

Printer Tasks

Online

PapSize

Verify that all trays have the correct paper size loaded.
Select the drawer using N. The selection is highlighted (for example, tray1size).
Press P and a list of sizes appears on the Control Panel (Figure 3-10).
Contination arrows

tray1size =

Online
Online

LETTER
LEGAL
LEDGER
EXECUTIVE
A4
A5
Select

Figure 3-10 Paper Size Selection

Printer Tasks

3-7

Adjusting Custom Tray Paper Guides

Use M or N to move to the correct paper size (Figure 3-11).

tray1size

A3
JISB4
JISB5
CUSTOM

Online

Select

Figure 3-11 Paper size selection continuation

Press Select to choose the desired size and then press Online to save your choice and
return to a Ready -- Free state.

Adjusting Custom Tray Paper Guides
Note The D640 printer does not support printing on envelopes. Do not use the custom paper
tray to feed envelopes or paper jams will result.

Note You can use standard paper sizes in the custom trays. Set the Control Panel settings to
the standard paper size, not the custom size.
The custom paper tray (product number C5634A) holds paper that has minimum dimensions of
4.75 x 7.2 in (120 x 182 mm) up to 11.7 x 17 in (297 x 431.8 mm). For additional information
regarding paper stock, see “Using Paper” on page D-1.

3-8

Printer Tasks

Adjusting Custom Tray Paper Guides

Adjust the guides to the size of your paper. Figure 3-12 shows the adjustment guide
travel directions.

Thumbscrews to adjust
left guide (finger tighten)

Printer Tasks

Squeeze lever to release
front and rear guides

Figure 3-12 Custom Paper Tray guide adjustments

2.
3.

Load the paper in the tray as described in “Loading Paper Into Trays and HCI” on
page 3-16.
Do not stack the paper above the "paper full" mark, as this may cause paper jams or
skewed print.

Note Never mix the types of paper loaded in a tray. Intermixing paper can result in paper
handling problems.
4.

Adjust the guides to fit closely, but not too tightly. A tight fit binds the paper and can
cause misfeeds.

Printer Tasks

3-9

Setting Custom Paper Sizes

Setting Custom Paper Sizes
The custom paper tray can accommodate a wide range of paper sizes, using continuously
adjustable paper guides.
The custom paper tray can accommodate paper stock as small as 4.75 x 7.2 inches (120 x 182
mm) or as large as 11.7 x 17 inches (297 x 431.8 mm). You can install one or more custom
trays in the printer, but they must all be set to the same size.
There are two tasks in setting up custom paper sizes in the custom tray:
• Define the custom tray.
• Set the paper size in the printer menu settings. (Save the dimensions and menu numbers in
case you must refill the tray at some other time.)
1. To specify a tray as the custom tray, press PapSize on the Main Screen (Figure 3-13) to
display the screen shown in Figure 3-14. This display identifies the paper size in each
tray.

Ready - - free
JUN 18 05:32.23
PCL
Offline
Online
Offline

Message field

600dpi

Printer is offline
Custom

Test

Figure 3-13 Main Screen

Press M or N to highlight the tray to define as a CUSTOM tray.

PapSize

Online
Online
Figure 3-14 Paper tray selections

3-10 Printer Tasks

tray1size
tray2size
tray3size

=LETTER
=LETTER
=LETTER

LTR
LTR
LTR
PapSize

Configuring Custom Tray Menu Settings

Press P to get a list of paper sizes for this tray, as shown in Figure 3-15.
Contination arrows

tray1size =

Online
Online

LETTER
LEGAL
LEDGER
EXECUTIVE
A4
A5
Select

Figure 3-15 Paper size selections

Press N to move to CUSTOM.
Press Select to define this CUSTOM paper size selection (Figure 3-16).

tray1size

Printer Tasks

4.
5.

A3
JISB4
JISB5
CUSTOM

Online
Online

Select

Figure 3-16 Paper size (continuation of selections)

Press Online to return to the Main Screen.

Configuring Custom Tray Menu Settings
You must first interpret your paper dimensions into settings the printer can understand.
Basically, you must accurately measure your paper’s width and height (also called length)
using standard inches (inches) or millimeters (mm), and converting the numbers into printer
units.
For example, using a 5 x 8 inch card:
1.
2.

The card is printed with the short side (5 in) as the leading edge. The menu setting for
the leading edge is width.You could also select the long side as the width.
The 8 inch side is height. You could also select the short side as the height.

Printer Tasks 3-11

Configuring Custom Tray Menu Settings

5.
6.

The printer has many printer unit options. (A unit is simply a measure of size used to
give you fine control over image placement on the page.)
For most jobs sized in inches, use 1/100" as the unit size.
Multiply your paper height (length) by the number of units per inch (in our example, 100
x 8 = 800).
If you use a unit size of 1/200", the number would be 1600; if the unit size was 1/720",
the number would be 5760, and so on. If you are using the mm unit setting, no multiplication is necessary.
Multiply your paper width by the number of units per inch (in our example,
100 x 5 = 500).
Press Menu on the Main Screen to display the Menu options, shown in Figure 3-17.

Printing
Configuration
PCL
Comms
Maintenance

Online
Online
Figure 3-17 Menu options

7.
8.
9.

Press N to highlight Configuration.
Press P to get Configuration options (Figure 3-18).
Press N to select units. (Figure 3-18).

Configuration

Online
Online
Figure 3-18 Configuration options

3-12 Printer Tasks

newline = CR+LF
traylock
sizes = CONFIRM
imageshift
customsize
units = 1/720"

Configuring Custom Tray Menu Settings
10. Press M or N to select your unit size selections (Figure 3-19).

Configuration.units

Online

1/100"
1/200"
1/300"
1/600"
= 1/720"
MM

Online

Select

Figure 3-19 Unit size selections

11. In our example, 1/100" is highlighted (Figure 3-20).

Online

1/100"
1/200"
1/300"
1/600"
1/720"
MM

Online

Printer Tasks

Configuration.units

Select

Figure 3-20 Highlighting 1/100"

12. Press Select. Figure 3-20 is displayed.
13. Press M to highlight customsize (Figure 3-21).

Configuration

Online

newline = CR+LF
traylock
sizes = CONFIRM
imageshift
customsize
units = 1/100"

Online
Figure 3-21 Customsize selection

Printer Tasks 3-13

Configuring Custom Tray Menu Settings
14. Press P to highlight width.

Configuration.customsize

width = 8416
height = 12240

Online
Online
Figure 3-22 Customsize width and height selections

15. Press M or N until your number is highlighted (our example is 500, as shown in
Figure 3-23).

Configuration.customsize

width

Online
Online
Figure 3-23 Width selection for custom paper size

16. Press Select.
17. Press N to highlight height.

3-14 Printer Tasks

= 500
501
502
503
504
505
Select

Configuring Custom Tray Menu Settings
18. Press M or N until your number is highlighted (our example is 800, as shown in
Figure 3-24).

Configuration.customsize

Online

height = 800
801
802
803
804
805

Save

Select

Figure 3-24 Height selection for Custom Paper Tray

Printer Tasks

19. Press Select.
20. Press Save.

Printer Tasks 3-15

Loading Paper Into Trays and HCI

Loading Paper Into Trays and HCI
This section explains the proper paper loading process, which depends on the type of paper
used and the print job requirements.
Follow these basic guidelines to select and use paper and other media (transparencies, labels,
etc.) for the D640:
• Use only paper labeled specifically for non-impact or laser printing, xerographic copying,
or duplicating. Refer to “Media Selection Specifications and Guidelines” on page D-3 for
complete media specifications.
• Use only one kind of paper in a tray at a time; mixing types of paper can cause jams.
• Do not overfill the paper trays or HCI (note the maximum fill line).
• The HCI is supported for use with paper media only.

Opening Paper
Remove the paper from the package, with the package seam side up, as shown in
Figure 3-25. Read the manufacturer’s packaging end-label and note the direction of the
arrow. The arrow points to the side that should be printed first, also referred to as the
face side.

THIS

SIDE

FIRST

Figure 3-25 Removing paper from the package

2.
3.

Inspect the paper for indented or interlocked edges, bent corners, wrinkled sheets, and
excess glue from the wrapper. Discard any damaged sheets.
Load the paper into the printer tray or HCI as recommended in the paper loading
illustrations provided in Table 3-2.

3-16 Printer Tasks

Loading Paper Into Trays and HCI

Table 3-2

Paper orientation in trays and HCI
Input Tray
HCI
Short edge leading

Long edge leading

TOF

Single-sided
printing to
output tray
or
Double-sided
printing to HCO

Face down

Face up

Face down
TOF

TOF = Top Of
Form

TOF

Face up

Face down

TOF

Tip Use the arrow on the paper package as a guideline for loading paper. For the HCI, load
paper so that the arrow on the package is pointing upward. For trays, load paper so that the
arrow on the package is pointing downward.

Printer Tasks 3-17

Printer Tasks

Double-sided
printing to
output tray

Locking Paper Trays

Locking Paper Trays
All paper sources with the same size of media are automatically linked together. This means
that the printer will automatically switch to the next tray when the current tray runs out of
paper. This could cause problems when all of the paper trays are set to the same size of paper,
but contain different types of paper, such as plain paper and letterhead.
In order to eliminate the linking of trays, you must "lock" the trays you don’t want selected
unless the job gives a direct command to use paper from that source.
For example, if you have a tray with letterhead paper in it, you may want to lock out this tray
so that if the other trays run out of paper, the letterhead paper tray would not be used.
The printer does not detect the paper size loaded in a particular tray.
Follow this procedure to lock a paper tray:
1.
2.

On the Main Screen, press Menu.
Press N to move to Configuration (Figure 3-26).

Online
Online
Figure 3-26 Configuration Menu

Press P to select Configuration.

3-18 Printer Tasks

Printing
Configuration
PCL
Comms
Maintenance

Locking Paper Trays

Press N to move to traylock (Figure 3-26).

Configuration =

Online
Online

newline = CR + LF
traylock
sizes
= CONFIRM
imageshift
customsize
units
= 1/720"

Figure 3-27 traylock

Press P to select traylock.
Press M or N to move to the tray to lock (Figure 3-28).

Configuration.traylock

tray1
tray2
tray3

Printer Tasks

5.
6.

=UNLOCKED
=UNLOCKED
=UNLOCKED

Online
Online
Figure 3-28 Configuration.traylock

Printer Tasks 3-19

Locking Paper Trays

For example, if you want to lock tray1, press P to select tray1. (See the screen in
Figure 3-29.)

Configuration.traylock.tray1 =

tray1 = UNLOCKED
LOCKED

Online
Online

Select

Figure 3-29 Configuration.traylock.tray1

8.
9.

Press N to move to locked.
Press Select. You return to the Configuration.traylock screen with tray1 locked
(Figure 3-30).

Configuration.traylock

tray1= LOCKED
tray2 = UNLOCKED
tray3 = UNLOCKED

Online
Save

Figure 3-30 Tray 1 locked

10. Press Save to save the changes in PwrOnConfig.

3-20 Printer Tasks

Stopping or Interrupting Print Jobs

Stopping or Interrupting Print Jobs
The printer works in three basic states: processing incoming data, imaging the data, and
printing the data. When the printer is in one of these states, the Main Screen changes to reflect
the new state, as shown in Figure 3-31, and the Test button changes to the End button.

Ready - - printing
JUN 18 05:32.23
PCL
Cen

600dpi
LTR
LTR
LTR

Online
Offline
Offline

End

If you want to stop or interrupt the print job in progress, press the End button. When you press
End, you will see the End submenu, as shown in Figure 3-32.

End =

Online
Online

PAUSE
ENDDOC
SUPPRESS
ABANDON

Select

Figure 3-32 End Submenu

Printer Tasks 3-21

Printer Tasks

Figure 3-31 End Button

Clearing a Paper Jam

The choices available are:
PAUSE

Temporarily stops the job. Use this to pause the printer, such as when adding or
removing paper or adding toner.

ENDDOC

Any incomplete or partial pages are printed (like a form feed or page eject). The job
ends normally and the printer is ready for another job. This is typically used when the
print job has no end-of-job command, and the Control Panel displays Ready -- wait
for a long time.

SUPPRESS

Continues to process the current job, but the resulting pages are not printed. Printing
resumes with the next job. Select SUPPRESS when you no longer want to print the
current job, but you want to retain data, such as downloaded fonts and macros,
needed for future jobs. SUPPRESS is the recommended way to end routine print
jobs.

ABANDON

Ends processing of the current job and clears all data in the input buffer. This is the
most direct, quickest, and potentially risky way of stopping a current job. Use
ABANDON only when you are certain that the data in the print job is not required by
future print jobs.

Clearing a Paper Jam
When you start a print job, the printer selects paper, a page at a time, from one of the internal
trays or from the external HCI. Paper jams may occur if the paper is wrinkled, folded, skewed,
or out of specification. The printer goes Offline until the paper jam is cleared.
When a jam occurs, refer to the Control Panel for a visual and written description of the jam
location. For a visual indication refer to the picture on the right side of the Control Panel. The
area in the paper path where the jam occurred will be blinking.
More than one sheet of paper may be located in the paper path; all sheets must be removed
before the printer will resume printing.
In this case, the paper path diagram may continue blinking in the same or another location, and
the printer displays messages about the location of remaining sheets until all jams are cleared.
Note

The printer is forced Offline until the problem is fixed.

Table 3-3 lists each paper jam that displays on the Control Panel and how to clear the jam.
More detailed information on clearing paper jams appears on the pages listed. You can also
refer to the illustrated jam clearing pictures located on the inside of the printer’s front door.

3-22 Printer Tasks

Clearing a Paper Jam

Table 3-3

Paper jams and remedies

Paper Jam Messages

Refer to
page

Remedy

Paper Input Jams

TRAY1 Pick error Remove tray (1, 2, or 3), remove paper jam from paper entry
TRAY2 Pick error area and/or within tray.
TRAY3 Pick error

3-24

Feed jam 1 Open the front door, lower transfer assembly, rotate knob 1

3-26

counterclockwise and knob 2 clockwise to free paper,
remove jammed paper.

Feed jam 2 Open the side door, remove jammed paper.
HCI jam 1 Open HCI, lower paper, remove jammed paper.

3-32

HCI jam 2 Pull HCI away from printer, remove jammed paper.

3-34

HCI jam 3 Pull HCI away from printer, remove jammed paper.

3-34

HCI jam 4 Open the front door, lower transfer assembly, rotate knob 1

3-26

counterclockwise and knob 2 clockwise to free paper,
remove jammed paper.
Paper Path Jams

Fuser unit jam 1 Open the front door, lower transfer assembly, open lever 4,
Fuser unit jam 2 push decurler lever down, remove jammed paper to the

3-36

right.

Duplex path jam 1 Open the front door, raise lever 6, and remove jammed
Duplex path jam 2 paper. You may need to turn duplex roller knob to release

3-38

Print unit path jam (Reversing unit area jam)

3-40

the paper.

Open the front door, open lever 4, hold lever 5 away from
the fuser, and remove jammed paper. You may need to turn
duplex roller knob to release the paper.
Paper Output Jams

Ejection unit jam 1 Raise the paper ejection cover and remove jammed paper.
Ejection unit jam 2

3-43

HCO jam 1 Open the HCO door, rotate roller knob 1 to free paper, then
HCO jam 2 lift levers to remove paper.

3-45

Printer Tasks 3-23

Printer Tasks

3-26

Clearing Paper Input Jams

Clearing Paper Input Jams
Clearing a Tray Pick Error Jam
When the printer tries to load a sheet of paper from one the paper trays and encounters a
picking problem, the Control Panel shows a blinking section at the output of the problem tray
as shown in Figure 3-33.

**** Pick error
Remove paper & Press Clear
PCL

600dpi
LTR
LTR
LTR

Offline
Offline
Clear

End

**** TRAY1
TRAY2
TRAY3
Figure 3-33 Pick error jam indication

To clear the tray pick error:
1.

Open the indicated paper tray, as shown in Figure 3-34.

LTR

Figure 3-34 Opening paper tray

3-24 Printer Tasks

Blinking

Clearing Paper Input Jams

Examine the right side of the tray area, particularly the extreme upper right, where the
paper leaves the tray and is pulled into the paper path. There may be one or more pieces
of paper jammed in it. If there is no obvious jam, reach up into the upper right corner of
the tray, feel for paper stuck there, and remove any jammed paper. Pull gently, as the
paper could tear. Refer to Figure 3-35.
If you do not find any jammed paper, open the lower right cover and check for paper.

Lower right cover

LTR
LTR

Figure 3-35 Removing paper jam from tray area

Press Clear. If no other paper jam indications appear on the Control Panel, you are ready
to resume printing. If the Control Panel still shows a jam, search the area again, or the
area indicated on the Control Panel.

Printer Tasks 3-25

Printer Tasks

LTR

Clearing Paper Input Jams

Clearing a Feed Path Paper Jam
The feed path paper jam paper path is the path between the paper feed unit (pulls paper from
the trays or HCI) and the drum unit. A jam in this area will display feed path jam 1, jam 2 or
jam 4 depending on where the jam physically occurs.
Figure 3-36 shows the location of the Feed path paper jam indication on the Control Panel.

.............
Remove paper & Press Clear
PCL
Offline
Clear

Blinking

LTR
LTR
LTR
Menu

Test

PapSize

*****: Feed path jam 1
Feed path jam 2
Feed path jam 4
Figure 3-36 Feed path paper jam indication

1.
2.

Lower the right-side lower cover (Figure 3-37). If you have an HCI installed, unlatch
the HCI and slide it away from the printer (Figure 3-38).
Look for paper caught in the paper feed path at the top of the lower right cover opening.
Only a small area of the paper may be visible. If you see paper, remove it.

3-26 Printer Tasks

Clearing Paper Input Jams

Paper

LTR

Printer Tasks

LTR

Lower right door

Figure 3-37 Removing paper from side door opening

LTR

Figure 3-38 Unlatching the HCI

Printer Tasks 3-27

Clearing Paper Input Jams

3.
4.
5.

If there is no paper there, close the door and if applicable, push the HCI inward to relatch
it.
Open the front door. Note that the inside of the front door has a set of labels showing
various paper jam remedy procedures. Use these as a guide to clearing paper jams.
Refer to Figure 3-39. Pull out gently on Handle 3 to unlatch and release the Transfer
Guide. Gently lower the Transfer Guide and let it rest on the bottom of the printer’s
interior.

Handle 3

Figure 3-39 Lowering Transfer Assembly

3-28 Printer Tasks

Clearing Paper Input Jams

If you can see the paper jam, reach up and remove it, as shown in Figure 3-40.

Figure 3-40 Paper removed from under Drum Unit

7.
8.

If the paper is not visible, reach into the area indicated in Figure 3-40 and feel for it.
Turn knob 1 counterclockwise and knob 2 clockwise to move paper into position for
removal, as shown in Figure 3-41.

Printer Tasks 3-29

Printer Tasks

Clearing Paper Input Jams

Knob 2

Knob 1

Figure 3-41 Turning Knobs 1 and 2

If paper is visible, reach in and remove it. If it is not visible, you may need to reach in
and search by hand.

Caution Remove any jewelry on your hand or wrist before reaching into the printer. Be
careful not to scratch the drum as you feel for the paper.

3-30 Printer Tasks

Clearing Paper Input Jams

Figure 3-42 Replacing Transfer Assembly

11. If no other paper jam indications appear on the Control Panel, you are ready to resume
printing. If the Control Panel still shows a jam, search the area again, or the area
indicated on the Control Panel.

Printer Tasks 3-31

Printer Tasks

10. Raise the Transfer Guide until it latches into position, as shown in Figure 3-42, and
close the door.

Clearing Paper Input Jams

Clearing HCI Jams
When the printer tries to obtain a sheet of paper from the HCI and the paper fails to load
properly, this is an HCI paper jam. This is indicated on the Control Panel by the blinking paper
path shown in Figure 3-43.
• HCI jam 1(pick error), a jam where the paper did not leave the HCI correctly.
• HCI jam 2 (jam), a jam where the paper did not enter the printer correctly.
• HCI jam 3 (jam), a jam where the paper is between the printer and the HCI.

600dpi

HCI jam 2
Remove paper & Press Clear
PCL
Cen
Offline
Offline
Offline
Figure 3-43

LTR
LTR
LTR
Menu

Blinking

LTR

End

HCI paper path jam indication

Clearing HCI Jam 1
1.

If the Control Panel indicates an HCI jam 1 (a pick error), open the HCI door as shown
in Figure 3-44. Press the button on top of the HCI to lower the paper stack.

LTR

Figure 3-44 Opening the HCI door

3-32 Printer Tasks

Clearing Paper Input Jams

Inspect the top of the HCI paper stack for jammed paper and remove any sheets that are
stuck in the paper ejection area or which look crumpled or otherwise defective, as shown
in Figure 3-45.

LTR

Close the HCI door as shown in Figure 3-46. The paper rises up to the operating
position automatically.

LTR

Figure 3-46 Closing the HCI door

Press Clear. If there is no paper jam indication, you are ready to resume printing. If the
Control Panel still shows a jam, search the area again, or the area indicated on the
Control Panel.

Printer Tasks 3-33

Printer Tasks

Figure 3-45 Removing paper from HCI

Clearing Paper Input Jams

Clearing HCI Jam 2
If the Control Panel shows an HCI jam 2, there may be paper jammed between the HCI and the
printer.
Squeeze the HCI top handle to release the HCI from the printer and then pull it away as shown
in Figure 3-47.

LTR

Figure 3-47 Releasing the HCI from the printer

If there is paper hanging out of the printer or the HCI, remove it, as shown in
Figure 3-48:

LTR

Figure 3-48 Removing paper between the HCI and the printer

3-34 Printer Tasks

Clearing Paper Path Jams

6.
7.

Push the HCI towards the printer until it latches and check the Control Panel.
Press Clear. If there is no paper jam indication, you are ready to resume printing. If the
Control Panel still shows a jam, search the area again, or the area indicated on the
Control Panel.

Clearing Paper Path Jams
Once the paper has cleared the feed mechanisms, which carry the paper up to the drum unit,
there are places where jams can occur between the drum unit and the area just before the
ejection unit. These areas are: at the fuser, in the duplex path, and the print unit path around the
reversing unit. This is indicated on the Control Panel by the blinking paper path shown in
Figure 3-49.

600 dpi

Offline
*Offline*
Clear
*****:

Blinking

LTR
LTR
LTR
Menu

Test

PapSize

Fuser unit jam
Duplex path jam
Print unit path jam

Figure 3-49 Paper path jams indication

Printer Tasks 3-35

Printer Tasks

Remove paper & Press Clear
PCL

Clearing Paper Path Jams

Clearing a Fuser Unit Jam
The fuser unit jam is located after the drum.
1.

Open the front door and lower the Transfer Assembly, as shown in Figure 3-50.

Lever 4

Figure 3-50 Lowering Transfer Assembly

2.
3.

Turn Lever 4 fully clockwise (straight down) until stopped to relieve tension on the
paper, as shown in Figure 3-50.
Look for a sheet or sheets of jammed paper on the right side of the fuser unit. While
pressing the decurler lever with your left hand, reach in and remove any jammed paper
with your right hand, as shown in Figure 3-51.

3-36 Printer Tasks

Clearing Paper Path Jams

Thumb on
decurler lever

After you have removed the paper, raise the Transfer Guide, return Lever 4 to the
horizontal (closed) position (as shown in Figure 3-52), and close the door.

Figure 3-52 Closing Lever 4 and securing the Transfer Assembly

If no other paper jam indications appear on the Control Panel, you are ready to resume
printing. If the Control Panel still shows a jam, search the area again, or the area
indicated on the Control Panel.

Printer Tasks 3-37

Printer Tasks

Figure 3-51 Removing Fuser Unit paper jam using Decurler Lever

Clearing Paper Path Jams

Clearing a Duplex Unit Jam
The duplex unit jam is indicated on the Control Panel as shown in Figure 3-53.

Blinking
600dpi

Duplex path jam 2
Remove paper & Press Clear
PCL
Offline
Clear

LTR
LTR
LTR
Menu

End

Figure 3-53 Duplex Unit Paper Jam

1.
2.

Open the door and locate lever 6 as shown in Figure 3-54.
Lift lever 6 and turn the duplex roller knob to move any paper into view.

Duplex roller knob

Lever 6

Figure 3-54 Freeing Duplex Jam

3-38 Printer Tasks

Clearing Paper Path Jams

Remove paper as shown in Figure 3-55 and close the door.

Figure 3-55 Removing paper jam from duplex path

Printer Tasks 3-39

Printer Tasks

Clearing Paper Path Jams

Clearing a Reversing Unit Area Jam
The reversing unit area paper path jam is located to the left of the duplex unit.
1.

Open the front door and turn Lever 4 fully clockwise, shown in Figure 3-56. This
removes pressure on paper leaving the fuser unit area.

Lever 4

Figure 3-56 Opening Lever 4

Locate Lever 5 and push it downward and away from the fuser unit area, as shown in
Figure 3-57.

3-40 Printer Tasks

Clearing Paper Path Jams

Decurler roller knob

Figure 3-57 Freeing paper in Reversing Unit jam

3.
4.

If paper is not visible, turn decurler roller knob counterclockwise to move any paper into
view, or reach up into this area carefully.
Remove jammed paper, as shown in Figure 3-58.

Figure 3-58 Removing paper jam from reversing area

Printer Tasks 3-41

Printer Tasks

Lever 5

Clearing Paper Path Jams

Turn Lever 4 fully counterclockwise back into the closed position, as shown in
Figure 3-59, and close the door.

Figure 3-59 Closing Lever 4

3-42 Printer Tasks

Clearing Paper Output Jams

Clearing Paper Output Jams
Once the printed page is made, it is delivered to you outside of the machine. There are several
places in the ejection paper path where jams can occur. They are in the ejection unit and the
HCO.

Clearing an Ejection Unit Jam
Figure 3-60 shows the ejection unit jam indication on the Control Panel.

LTR
LTR
LTR
Menu

End

Printer Tasks

Offline
Offline
Clear

Blinking

600dpi

Ejection unit jam 2
Remove paper & Press Clear
PCL

Figure 3-60 Ejection Unit jam

Swing open the ejection unit cover as shown in Figure 3-61.

Figure 3-61 Opening the Ejection Cover

Printer Tasks 3-43

Clearing Paper Output Jams

Remove any jammed paper in the ejection unit cover area (Figure 3-62) and close the
cover.

Figure 3-62 Removing jammed paper from Ejection Cover area

3-44 Printer Tasks

Clearing Paper Output Jams

Clearing an HCO Jam
Jams can occur at the input to the HCO. Figure 3-63 shows the HCO jam error indication on
the Control Panel.

HCO jam 1
PCL
Cen

LTR
LTR
LTR

Offline
Offline
Offline

Blinking

600dpi

End

Open the front door and remove any jammed paper in the reversing area, as shown in
Figure 3-58.

Figure 3-64 Removing paper jam from reversing area

Printer Tasks 3-45

Printer Tasks

Figure 3-63 HCO paper jam indication

Clearing Paper Output Jams

Open the HCO door. Locate and turn knob 1 counterclockwise to move paper from the
input area to the lower section as shown in Figure 3-65.
HCO Knob 1

Figure 3-65 HCO Knob 1 Paper Input Roller

Pull lever 2 back (Figure 3-66) and remove any paper.

HCO
Lever 2

Figure 3-66 Clearing HCO lower section paper jam using Lever 2

3-46 Printer Tasks

Clearing Paper Output Jams

If jammed paper is not visible, lift lever 1 to see if there is paper jammed there. Rotate
knob 1 counterclockwise to move any paper into view. Remove any paper found as
shown in Figure 3-67.

Figure 3-67 Clearing HCO upper section paper jam using Lever 1

5.
6.

Close the HCO door.
If jammed paper is not visible, there may be paper jammed between the HCO and the
printer.
You’ll need to separate the HCO from the printer and check for jams. See the following
section for more information.

Printer Tasks 3-47

Printer Tasks

HCO Lever 1

Clearing Paper Output Jams

Separating the HCO and Printer
To separate the HCO from the printer:
1.

The printer physically connects to the HCO with a connecting pin, which fits into the
corresponding positioning hole on the HCO. See Figure 3-68.

Connecting
Pin

Positioning
Hole

Bracket B

Bracket A

Figure 3-68 Separating HCO and printer

Figure 3-69 shows detailed look at the connecting pin and the positioning hole.

Push HCO
left to disengage

Printer

Unscrew Bracket A

Pull HCO away from printer

Figure 3-69 Printer connecting pin and HCO positioning hole configuration

3-48 Printer Tasks

HCO

Handling Error Messages and Troubleshooting

3.
4.
5.

6.
7.

Unscrew bracket A, which connects the HCO to the printer.
Push the HCO to the left to disengage the connecting pin from the positioning hole.
Pull the HCO away from the printer. It is still connected by a cable, but you should only
need to move it far enough to see if there is paper jammed in the interval between the
machines. If you find paper there, remove it.
Push the HCO and the printer together and reseat the connecting pin in the positioning
hole.
Replace bracket A.
If no other paper jam indications appear on the Control Panel, you are ready to resume
printing. If the Control Panel still shows a jam, search the area again, or the area
indicated on the Control Panel.

Handling Error Messages and Troubleshooting

Printer errors that are caused by mechanical or electrical problems are also reported by specific
error codes. These problems require a service call to your service representative.
An error message is always accompanied by an action message, as shown in Figure 3-70.

Front door open
Close front door
PCL
12.145
Cen

Error message 600dpi
Action message
LTR
LTR
LTR

Online
Offline
Clear

Custom

Test

PapSize

Figure 3-70 Error reporting

Printer Tasks 3-49

Printer Tasks

An error message can be caused by mechanical problems, such as jams, or by incorrect
settings, such as specifying the wrong paper size from the wrong paper tray. These are typical
printer problems than can be easily cleared by the user.

Handling Error Messages and Troubleshooting

Error Reporting/Action Response
Refer to “Error Messages” on page A-7, for how to interpret error messages.
In the unlikely event that the printer has a major error, follow these steps:
1.
2.
3.
4.
5.

The printer may self-diagnose the problem and possibly display the message as shown in
Figure 3-71.
Write down the error code and message that appears on the Control Panel.
Refer to “Call Engineer Error Messages and Codes” on page A-8 to determine the
meaning of the error code.
If the error code calls attention to a specific physical component or location on the
printer, check the area specified and correct the problem.
If you cannot resolve the problem, call your service representative. Be prepared to give
the service representative the error code and any messages that appear on the Control
Panel to assist in troubleshooting.
Blinking
Error code

High-voltage power supply alarm
Call Engineer (SVC 6F)
PCL
Offline
Offline
Clear

LTR
LTR
LTR
Menu

Figure 3-71 Call Engineer (Service Representative)

3-50 Printer Tasks

End

4
Ordering and Replacing Consumables
Introduction
This chapter provides user maintenance procedures to maintain the printer’s consumables.
If you want:
•
•
•
•
•
•
•
•

Go to:

An overview of the D640 printer supplies
To order additional consumables
To replace toner or recycle toner after replacement
To replace developer and ozone filter
To replace the drum and transfer assembly
To replace the fuser
To replace the printer pick rollers
To replace the HCI pick rollers

page 4-1
page 4-2
page 4-4
page 4-9
page 4-18
page 4-29
page 4-33
page 4-42

Overview of Consumable Supplies
You can replace all of the consumable supplies. This chapter presents step-by-step instructions
for removal and replacement of these supplies and explains how to set the printer to produce
lighter or darker prints.
• Each time you replace a consumable, the action is automatically recorded in the printer’s
online maintenance log.

Caution Hewlett-Packard recommends the use of Hewlett-Packard labelled consumable
supplies. Hewlett-Packard is not responsible for any failures or print quality issues arising
from the use of other than Hewlett-Packard supplies in the cut sheet printer. Such failures are
not covered under warranty or under the Hewlett-Packard service agreement.

Ordering and Replacing Consumables

4-1

Consumables

Caution Damage to the photoconductor can cause excessively light or dark printing or
missing text.

Ordering D640 Printer Consumables

Ordering D640 Printer Consumables
You can order consumables directly from Hewlett-Packard by calling 1-800-538-8787 in the
United States and Canada. Customers outside the United States and Canada should contact
their local Hewlett-Packard sales office.
Please plan for a two to five day delivery in the United States, possibly longer outside the
United States. If your printer was purchased from a Hewlett-Packard reseller, you may be able
to purchase consumables directly from them.
Table 4-1 lists the D640 printer consumables, ordering numbers, kit content descriptions and
quantities, along with the length of time you can expect them to last under optimum operating
conditions.
Use the replacement cycle estimates in Table 4-1 to plan your initial consumable purchases.
Because yields may vary widely from the estimates, you should track your actual usage to
establish proper replacement schedules for each printer installation.
Actual yields depend upon:
•
•
•
•
•
•
•

Media (paper type, weight, chemical composition, perforations, paper dust, and quality).
Media storage factors such as care and handling, room temperature, and humidity.
Exposure to light (photoconductor drum).
Frequency of cleaning the printer.
Average print job size, daily print volume, and patterns of printing.
Ambient environmental conditions, such as temperature, humidity, and static electricity.
Power-on hours.

“Managing Consumables” on page 6-6 describes some of the considerations in using and
replacing consumables.

4-2

Ordering and Replacing Consumables

Ordering D640 Printer Consumables

Table 4-1
Item
Toner Kit

Developer Kit
Drum Kit

Consumables, product part numbers, and replacement cycles
Product
Number
C5626A

C5632A
C5629A

Contents

Qty

Replacement Cycle
(Estimated)

Shelf
Life
18 months

Toner bottles

8 each

Up to 180,000 page sides

Collector bottles

8 each

Note:

Cleaning rollers

4 each

Developer bottles

2 each

Ozone filter

1 each

Photoconductor
drum

1 each

Transfer unit

1 each

Cleaning wipes

1 pkg

Yield based on 4%
toner coverage

Up to 250,000 page sides

18 months

Up to 195,000 page sides

18 months

Fuser Kit

C5627A

Fuser, 120-127 VAC

1 each

Up to 300,000 page sides

Fuser Kit

C5628A

Fuser, 200-240 VAC

1 each

Up to 300,000 page sides

Printer Pick
Roller Kit

C5633A

Printer pick rollers

1 set

Up to 500,000 pages

HCI Pick
Roller Kit

C5636A

HCI pick rollers

1 set

Up to 500,000 pages

Note:

Inf.

Replacement cycles based on letter or A4 sized media. Larger sized media require more frequent
replacement.

Consumables

Note A new printer will report toner low and need to be refilled the first time after printing
about 6,000 images. This is normal and is due to the toner hopper being completely empty in a
new printer.
The estimated yields listed are not a warranty or guarantee of minimum life and are provided to
assist in initial supplies planning. Yields may vary widely based on applications and operating
conditions.
Yield estimate are based on, but not limited to, ideal environmental and operating conditions,
print jobs averaging 4% toner coverage per page, and an average job of 25 pages.

Ordering and Replacing Consumables

4-3

Replacing Toner

Replacing Toner
The toner comes in a kit that contains bottles of toner, empty toner collector bottles, and fuser
cleaning rollers. The toner collector bottle is replaced with every bottle of toner. The fuser
cleaning roller is replaced after every two bottles of toner.
Note

Replace the cleaning roller every other toner replacement.

Caution Only add toner when the printer displays a toner low or toner empty message.
Never try to add toner before the printer requires it. Never add more than one bottle of toner.
Overfilling causes toner spills.
When the toner starts to get low, the Control Panel displays:
Toner Low
Add New Toner

A Toner Low condition does not stop the printer. Toner can be added between jobs or during a
job by pressing Offline:
1.
2.

Press Offline.
Open the upper right cover (Figure 4-1) to access the toner hopper and toner collector
bottle.

..........
......

Toner collector bottle

Toner hopper

Upper right cover open

Figure 4-1

4-4

Opening Upper Right Cover

Ordering and Replacing Consumables

Replacing Toner

When the printer is in a toner low or toner empty condition, opening the upper right
cover displays the following text on the Control Panel:
Toner Replacement
Add new toner
and replace toner collector
then close right cover

3.
4.
5.

Locate the toner kit.
Remove a toner bottle.
Open the toner fill flap (front flap), as shown in Figure 4-2.
Toner fill flap

Figure 4-2

Check the top of the toner bottle to make sure it is closed. Shake the contents of the toner
bottle to loosen any toner that has settled and packed during shipment.
Line up the guide pins on the bottle with the guide pin openings on the toner fill
opening. Insert and turn the toner bottle clockwise 180° to start filling, as shown in
Figure 4-3.

Consumables

Opening the Toner Fill Flap and shaking the Toner Bottle

Ordering and Replacing Consumables

4-5

Replacing Toner

Empty toner bottle

Toner bottle

Handle

Guide pin

Figure 4-3

Filling the toner and removing the Toner Bottle

Note It will take about 30 seconds for the toner to empty into the toner hopper. Because the
toner bottle is translucent, you should be able to see the toner empty out of the bottle.
8.
9.

When empty, turn the toner bottle counterclockwise 180° and remove, as shown in
Figure 4-3.
Close the toner fill flap, as shown in Figure 4-4.

Toner fill flap

Figure 4-4

Closing the Toner Fill Flap

10. Discard the toner bottle. The toner bottle is made of recyclable materials. Dispose of it
according to local regulations.

4-6

Ordering and Replacing Consumables

Replacing Toner

Replacing the Toner Collector Bottle
If you have toner recycling turned on, you can skip this step. For information about toner
recycling, refer to “Managing Consumables” on page 6-6.
When you replace the toner, remove the old toner collector bottle and replace it with a new,
empty one. Refer to Figure 4-5 for an illustration of the toner collector bottle location.

Pull out old bottle

Insert new bottle

Figure 4-5

Toner Collector Bottle Replacement

Dispose of the old toner collector bottle in accordance with local regulations. Close the upper
right cover.

Replacing the Cleaning Roller (When Indicated on Control Panel)
WARNING!

Handle the old cleaning roller carefully, as it may be hot.

Replace the cleaning roller during every other toner replacement, as directed on the Control
Panel.
Open the front door.
Pull out the old cleaning roller, as shown in Figure 4-6.

Consumables

1.
2.

Ordering and Replacing Consumables

4-7

Replacing Toner

Cleaning roller

LTR

Figure 4-6

Removing the Cleaning Roller

Insert the new cleaning roller until it clicks into place, as shown in Figure 4-7.
Cleaning roller

LTR

Figure 4-7

4-8

Inserting the Cleaning Roller

Ordering and Replacing Consumables

Replacing Developer

4.
5.

Close the front door.
Press Done to return the printer Online.

Replacing Developer
Change the developer when it has either reached end-of-life, or diagnostic procedures have
identified it as a source of problems.
When the developer has reached end-of-life, the Control Panel will display:
Developer at end of life
replace developer

The printer does not stop, but it continues to display the message until you replace the
developer.
Note To avoid possible damage, the printer will stop printing about 40,000 pages after the
"Developer at end life" message first appears.
Replace the ozone filter during every other developer replacement.
Follow these steps for the developer replacement procedure:
1.
2.
3.

Discharge old developer.
Add new developer. (“Adding New Developer” on page 4-12).
Replace the ozone filter (“Replacing the Ozone Filter” on page 4-17).

Discharging Developer
1.

Press Menu on the Main Screen. Figure 4-8 is displayed.

Printing
Configuration
PCL
Comms
Maintenance

Online

Figure 4-8

Consumables

Online
Menu

Ordering and Replacing Consumables

4-9

Replacing Developer

Use N to highlight Maintenance, as shown in Figure 4-9.

Printing
Configuration
PCL
Comms
Maintenance

Online
Online
Figure 4-9

Maintenance

Use P to display Maintenance selections as shown in Figure 4-10.

Maintenance

Online

replace
alignment
density
= 10
testpages = 30
monitor
= OFF
date-time

Online
Figure 4-10 Maintenance selections

Use P to display replace selections, as shown in Figure 4-11. Developer is shown
selected.

Maintenance.replace

Online

DEVELOPER
DRUM UNIT
FUSER UNIT
TRAY1ROLLERS
TRAY2ROLLERS
TRAY3ROLLERS

Online
Figure 4-11 Replace selections

4-10 Ordering and Replacing Consumables

Select

Replacing Developer

Press Select to display Developer instructions, as shown in Figure 4-12.

Developer Replacement
Prepare new developer
and press Start
to discharge old developer

Start

LTR
LTR
LTR
Exit

Figure 4-12 Discharge Developer

6.
7.

Press Start, as shown in Figure 4-12.
The old developer is cycled into the empty developer bottle. The process takes about 45
seconds. Do not open any covers or cycle power during this period. Follow the
instructions on the Control Panel.

Blinking

Developer discharge
Developer discharging
Please Wait

Online

Consumables

Figure 4-13 Developer discharging

Ordering and Replacing Consumables 4-11

Replacing Developer

After 45 seconds, you see the display shown in Figure 4-14.

Blinking

Developer discharge completed
Prepare new developer bottle
Open upper right cover
Press Done

Online
Done

Figure 4-14 Developer discharge complete

Press Done.

Adding New Developer
1.

Open the upper right cover and locate the developer bottle as shown in Figure 4-15.

..........
......

Developer collector bottle

Upper right cover

Figure 4-15 Developer and Developer Collector Bottle

4-12 Ordering and Replacing Consumables

Replacing Developer

Remove the developer collector bottle, as shown in Figure 4-16.

Figure 4-16 Removing Developer Collector Bottle

3.
4.
5.

Move the bottle cap from the storage position onto the collection hole to close the bottle,
as shown in Figure 4-16.
Discard the developer collector bottle. The developer collector bottle is made of
recyclable materials; dispose of it in accordance with local regulations.
The following text appears on the Control Panel:
Developer injection
Open rear flap
Insert New Developer bottle
Press Done when bottle empty

Locate a new bottle of developer.

Consumables

Ordering and Replacing Consumables 4-13

Replacing Developer

Open the developer fill flap, as shown in Figure 4-17.
Developer fill flap

Figure 4-17 Opening the Developer Fill Flap

Caution
8.

Never reinstall used developer. Doing so may result in poor print quality.

Line up the guide pins on the new developer bottle with the guide pin openings on the
developer fill. Insert and turn the developer bottle clockwise 180° to start filling, as
shown in Figure 4-18.
Developer bottle

Developer bottle

Guide pin
Guide pin slot

Figure 4-18 Filling the Developer and tapping the Developer Bottle

4-14 Ordering and Replacing Consumables

Replacing Developer

Gently tap the developer bottle to dislodge any remaining developer, as shown in
Figure 4-18.
10. Turn the developer bottle counterclockwise 180° and remove, as shown in Figure 4-19.

Empty developer bottle

Figure 4-19 Removing the Developer Bottle and closing the Fill Flap

11. Close the developer fill flap, as shown in Figure 4-19.
12. Press Done. The Control Panel displays:

Consumables

Developer injection complete
Remove and Cap Old Bottle
Install Empty New Bottle
Close Cover and Press Done

Ordering and Replacing Consumables 4-15

Replacing Developer

Installing Developer Collector Bottle
1.
2.

Remove small cap on the side of the developer collector bottle.
Turn cap around and place in the storage location, as shown in Figure 4-20.

Empty bottle

Figure 4-20 Installing Developer Purge Bottle

Insert developer collector bottle into storage position.

Note The developer collector bottle will not fit if you forget to move the small cap to its
storage location.
4.
5.

Close upper-right cover.
Press Done on the Control panel.

4-16 Ordering and Replacing Consumables

Replacing Developer

Replacing the Ozone Filter
Replace the ozone filter after every other developer replacement.
1.
2.

Locate the ozone filter packaged in the Developer Kit.
Remove the used filter from the filter holder and install the new one, as shown in
Figure 4-21.

Handle

Handle
Ozone filter

Ozone filter holder

Figure 4-21 Replacing the Ozone Filter

Discard the used filter. The filter is not made of recyclable materials; dispose of it in
accordance with local regulations.

Consumables

Ordering and Replacing Consumables 4-17

Drum Kit - Replacing Drum and Transfer Assembly

Drum Kit - Replacing Drum and Transfer Assembly
The drum and transfer charger are always replaced together. The drum is replaced when the
Control Panel indicates:
Drum at end life
Replace drum

Caution The drum surface is easily damaged. Avoid contact with the drum surface and
don’t expose the drum to light for extended periods of time. Scratches will appear as dark lines
or marks on the printed page. A scratched drum should be replaced.
This section provides maintenance procedures for:
• Removing the old transfer assembly and installing the new transfer assembly (See
“Removing the Transfer Assembly” on page 4-19).
• Removing the old drum and installing the new drum (See “Installing the Drum” on
page 4-24).

Setting Up the Printer for Drum Kit Replacement
1.
2.
3.
4.
5.
6.

Press the Menu button on the Main Screen.
Press N to highlight Maintenance.
Press P to display Maintenance selections.
Press P to enter the Replace submenu.
Press N to highlight DRUM UNIT.
Press P to display drum instructions as shown in Figure 4-22.

Drum Replacement
Replace Drum unit
and Press Done

Online
Done
Figure 4-22 Replace Drum

4-18 Ordering and Replacing Consumables

Drum Kit - Replacing Drum and Transfer Assembly

Removing the Transfer Assembly
1.
2.

Open the front door, if it is not already open.
While pulling Handle 3, carefully lower the transfer guide as shown in Figure 4-23.

Handle 3

LTR
Transfer assembly
guide

Consumables

Figure 4-23 Handle 3 and Transfer Assembly Guide

Ordering and Replacing Consumables 4-19

Drum Kit - Replacing Drum and Transfer Assembly

Push in and pull up on the transfer assembly to free it from the guide assembly as shown
in Figure 4-24. Lift the transfer assembly out of the guide assembly.

Caution As you handle the transfer assembly, take care not to touch or damage the
transfer wire.

Transfer assembly guide
Transfer assembly

Transfer assembly guide

Transfer assembly

Wire

Figure 4-24 Removing the Transfer Assembly

Discard the transfer unit.

4-20 Ordering and Replacing Consumables

LTR

Drum Kit - Replacing Drum and Transfer Assembly

Removing the Drum
1.

Turn drum locking knob counterclockwise two or three turns to unlock the drum, as
shown in Figure 4-25.
Twist thumbscrew

Lever b1

Handle 3

LTR

Consumables

Figure 4-25 Releasing the Drum

Ordering and Replacing Consumables 4-21

Drum Kit - Replacing Drum and Transfer Assembly

2.
3.

Rotate Lever b1 clockwise, as shown in Figure 4-26.
Use the drum handles on the top and front to pull it out, as shown in Figure 4-26.
Guide rails
Top handle

Lever b1

Front handle

Figure 4-26 Removing the Drum

Discard the used drum. The drum is an aluminum cylinder coated with non-hazardous
organic material. Dispose of it according to local ordinances.

4-22 Ordering and Replacing Consumables

Drum Kit - Replacing Drum and Transfer Assembly

Unpacking the New Drum
1.

Open the vacuum sealed bag containing the drum and remove it, as shown in
Figure 4-27.

Drum

Figure 4-27 Unpacking Drum and removing the Protective Cover

Hold the drum by the top handle, set it on a solid surface, and carefully remove the
protective cover, as shown in Figure 4-27.

Consumables

Caution Do not touch the surface of the drum. Finger prints and scratches on the surface of
the drum may adversely affect print quality.

Ordering and Replacing Consumables 4-23

Drum Kit - Replacing Drum and Transfer Assembly

Installing the Drum
1.

Make sure Lever b1 is in the OPEN position.
Use the drum handles on the top and front to insert the drum along the guide rails until it
stops, as shown in Figure 4-28. Push forward gently until the drum meets the positioning
pins.
Top handle

Guide rails
Drum alignment
pins

Front handle

Alignment
pin holes

Figure 4-28 Inserting the Drum

4-24 Ordering and Replacing Consumables

Lever b1

Drum Kit - Replacing Drum and Transfer Assembly

Gently push the drum onto the positioning pins (Figure 4-29).
(2) Drum Alignment Pins

Figure 4-29 Drum Alignment Pin locations

Consumables

Note Make sure the alignment pins on the printer line up with the alignment-pin holes on the
drum.

Ordering and Replacing Consumables 4-25

Drum Kit - Replacing Drum and Transfer Assembly

Maintain pressure on the drum and finger-tighten the drum locking knob clockwise to
engage the frame and secure the drum as shown in Figure 4-30.
Drum locking knob

LTR

Figure 4-30 Securing the Drum

Rotate Lever b1 counterclockwise to lock the drum in place.

4-26 Ordering and Replacing Consumables

Drum Kit - Replacing Drum and Transfer Assembly

Installing the New Transfer Assembly
1.

Remove the transfer assembly from its packaging.

Caution As you handle the transfer assembly, take care not to touch or damage the
transfer wire.
2.

Using the alignment pin located on the end of the transfer assembly, insert the alignment
pin of the transfer assembly into the left rail of the transfer assembly guide and push in
to the end of the guide as shown in Figure 4-31.
Transfer assembly guide
Transfer assembly

Transfer assembly guide

Transfer assembly

LTR

Wire

Consumables

Figure 4-31 Inserting the Transfer Assembly into the Guide

Ordering and Replacing Consumables 4-27

Drum Kit - Replacing Drum and Transfer Assembly

Secure the transfer assembly guide by lifting Handle 3 until it snaps into place as shown
in Figure 4-32.

Handle 3
Transfer assembly
guide

Figure 4-32 Securing the Transfer Assembly

4.
5.

Close the front door.
Use the drum kit packing materials to repack for disposal.

4-28 Ordering and Replacing Consumables

LTR

Fuser Kit - Replacing the Fuser

Fuser Kit - Replacing the Fuser
The fuser is replaced when the Control Panel indicates:
Fuser At End Life
Replace Fuser

This section provides maintenance procedures for removing the old fuser and installing the
new one.
Note
1.
2.
3.
4.
5.
6.

This procedure is applicable to both 120-127 VAC and 200-240 VAC fusers.
Press the Menu button on Main Screen.
Press N to highlight Maintenance.
Press P to display Maintenance selections.
Press P to display replace selections
Press N to select fuser.
Press Select to display fuser instructions, as shown in Figure 4-33.

Fuser unit Replacement
Replace Fuser unit and
Press Done

Online
Done

Consumables

Figure 4-33 Fuser instructions

Ordering and Replacing Consumables 4-29

Fuser Kit - Replacing the Fuser

Removing the Fuser
To remove the fuser:
1.
2.

Open the front door.
Turn the fuser locking knob counterclockwise several times to release the fuser, as
shown in Figure 4-34.
Fuser locking knob

LTR

Figure 4-34 Releasing the Fuser Locking Knob

WARNING!
3.

The fuser may be hot. Avoid touching the fuser surfaces labeled as hot.

Pull the fuser out, supporting it with your hand, as shown in Figure 4-35.

Fuser

LTR

Figure 4-35 Pulling the Fuser out

4-30 Ordering and Replacing Consumables

Fuser Kit - Replacing the Fuser

Installing the Fuser
1.
2.

Locate and remove the new fuser from its packaging.
Place the fuser’s leading edge into the guides, then push the fuser into the printer until it
stops, as shown in Figure 4-36.

Fuser

Consumables

Figure 4-36 Installing the Fuser

Ordering and Replacing Consumables 4-31

Fuser Kit - Replacing the Fuser

Maintain pressure on the fuser and finger-tighten the fuser locking knob clockwise to
engage the frame and secure the fuser into position as shown in Figure 4-37.
If the fuser does not seat properly, do not force it. Instead, refer to Figure 4-37 while
following the next two steps:
a) Hold the fuser up against the printer using light pressure.
b) Carefully rotate the decurler roller knob clockwise until you feel the gears turn
easily and the fuser seats flush against the printer. Tighten the fuser locking
knob.
Decurler roller knob
Fuser locking knob

Figure 4-37

4.
5.

Fuser Locking Knob and Decurler Roller Knob

Verify all locks and levers are secure and then close the front door.
Press Done.

4-32 Ordering and Replacing Consumables

Printer Pick Roller Kit - Replacing the Tray Pick Rollers

Printer Pick Roller Kit - Replacing the Tray Pick Rollers
Replace the pick rollers whenever the Control Panel indicates:
Pick Roller At End Life
Replace Pick Roller

or when you get excessive pick errors.
Each tray and the HCI contain pick rollers. The Control Panel will indicate which one requires
replacement. This procedure is applicable to all three printer trays (tray1, tray2, and tray3). For
the HCI replacement procedures, see “HCI Pick Roller Kit - Replacing the HCI Pick Rollers”
on page 4-42.

At the Control Panel
1.
2.
3.
4.
5.
6.

Press the Menu button on the Main Screen.
Press N to select Maintenance.
Press P to select Maintenance options.replace should be highlighted.
Press Select to enter the replace submenu.
Press N to select the set of tray rollers to be replaced.
Press Select.

Removing the Printer Pick Rollers (Upper and Lower)
1.

To reach the tray pick rollers more easily, remove all three trays from the printer and set
them aside, as shown in Figure 4-38 below.

Pick rollers
Tray1
Pick rollers
Tray2
Pick rollers

Figure 4-38 Removing Paper Trays - all trays removed

Ordering and Replacing Consumables 4-33

Consumables

Tray3

Printer Pick Roller Kit - Replacing the Tray Pick Rollers

Locate the thumb screw holding the steel plate over the lower tray roller assembly, as
shown in Figure 4-39.

Thumbscrew

Figure 4-39 Locating Thumbscrew

Unscrew the thumb screw holding the steel plate by rotating counterclockwise several
turns. Place this plate aside for later assembly. See Figure 4-40.

Figure 4-40 Unscrewing Plate

4-34 Ordering and Replacing Consumables

Printer Pick Roller Kit - Replacing the Tray Pick Rollers

Locate the blue plastic clip holding the lower rollers in place. Pull this clip off and set it
aside. See Figure 4-41.

Figure 4-41 Removing Lower Roller Clip

Pull the two lower rollers off of the lower shaft now. See Figure 4-42.

Consumables

Figure 4-42 Removing Lower Rollers from Shaft

Ordering and Replacing Consumables 4-35

Printer Pick Roller Kit - Replacing the Tray Pick Rollers

Locate the blue plastic clip holding the upper rollers in place. Pull this clip off and set it
aside. See Figure 4-43.

Figure 4-43 Removing Upper Roller Clip

Pull the upper roller assembly off of the upper shaft, as shown in Figure 4-44.

Figure 4-44 Removing Upper Roller Assembly

4-36 Ordering and Replacing Consumables

Printer Pick Roller Kit - Replacing the Tray Pick Rollers

New Printer Pick Roller Kit
1.

Unpack the new printer pick roller kit (Product Number: C5633A). See Figure 4-45.

Figure 4-45 Printer Pick Roller Kit

Installing the Printer Lower Pick Rollers
During installation of the lower rollers the torque limiter roller (a smaller lower roller with a
black color outside) must go on the lower shaft first, as shown in Figure 4-46.

Consumables

Figure 4-46 Installing Torque Limiter

Ordering and Replacing Consumables 4-37

Printer Pick Roller Kit - Replacing the Tray Pick Rollers

Install the smaller lower roller (torque limiter roller) so that the notch in the roller’s
plastic fits over the metal pegs on the shaft. When this roller is correctly in all the way,
the roller is locked and will not rotate. See Figure 4-47.

Notch correctly positioned to go
over metal peg

Roller correctly installed all the way,
with notch over the metal peg

Figure 4-47 Correct Torque Limiter placement

Install the larger lower roller on the same shaft. The larger roller (when correctly
positioned) fits onto two small plastic pegs on the smaller lower roller. You may need to
rotate the larger roller against the smaller roller until it snaps into place. See Figure 4-48.

Larger lower roller positioned on the
same shaft as the smaller roller
Figure 4-48 Correct Larger Lower Roller placement

4-38 Ordering and Replacing Consumables

Larger lower roller rotated to
engage plastic pegs on smaller

Printer Pick Roller Kit - Replacing the Tray Pick Rollers

Snap the blue plastic clip into place. It fits over a groove on the end of the shaft to secure
the lower rollers. See Figure 4-49. If you don’t see this groove, the rollers may not be
completely seated all the way onto the shaft.

Blue clip placed on lower
roller shaft

Blue clip snapped into place on
lower roller shaft groove

Figure 4-49 Blue Clip snapped into place

Installing the Printer Upper Pick Rollers
When you install the printer’s upper pick rollers, the slot on the pick roller assembly must mate
with the corresponding mounting tooth on the printer bracket. See Figure 4-50.

Metal tooth

Figure 4-50 Upper Pick Roller Assembly Slot and Mounting Tooth on printer

Ordering and Replacing Consumables 4-39

Consumables

Slot

Printer Pick Roller Kit - Replacing the Tray Pick Rollers

Install the new upper pick roller assembly over the shaft. See Figure 4-51.

Figure 4-51 Installing Upper Roller Assembly

5.
6.

Push the upper roller assembly all the way onto the shaft. You may have to jiggle the
assembly a little as you push it to seat it correctly.
Snap the blue plastic clip into place. It fits over a groove on the end of the shaft to secure
the upper roller assembly. If you don’t see this groove, the assembly may not be
completely seated all the way onto the shaft. See Figure 4-52.

Figure 4-52 Installing Upper Roller Clip

4-40 Ordering and Replacing Consumables

Printer Pick Roller Kit - Replacing the Tray Pick Rollers

Installing the Covers and Trays
1.

Attach the metal plate to the printer frame with the thumbscrew. Turn the thumbscrew
clockwise several turns until it is snug. Do not overtighten. See Figure 4-53.

Figure 4-53 Attaching Plate

Replace the three paper trays back into the printer, as shown in Figure 4-54.

3.
4.

Press Done on the Control Panel.
Perform the Paper Path Alignment procedure described in “Adjusting Paper Path
Alignment” on page 6-11.

Ordering and Replacing Consumables 4-41

Consumables

Figure 4-54 Installing Paper Trays

HCI Pick Roller Kit - Replacing the HCI Pick Rollers

HCI Pick Roller Kit - Replacing the HCI Pick Rollers
This section provides the procedures to remove and replace the HCI pick rollers. When the
HCI pick rollers need to be replaced the Control Panel indicates:
HCI Pick Roller At End of Life
Replace HCI Pick Roller

or when you get excessive feed errors from the HCI.
Note We recommend that you use a small flashlight to help you see the inside of the HCI
while working in it.

At the Control Panel
1.
2.
3.
4.
5.
6.

Press the Menu button on the Main Screen.
Press N to select Maintenance.
Press P to select Maintenance options. replace should be highlighted.
Press Select to enter the replace submenu.
Press N to select the HCI tray rollers. The HCI option only appears if the HCI is
installed.
Press Select.

Removing the HCI Pick Rollers (Upper and Lower)
1.

Release the HCI from the printer and slide the HCI back on its rails, as shown in
Figure 4-55.

LTR

Figure 4-55 Sliding HCI away from printer

4-42 Ordering and Replacing Consumables

HCI Pick Roller Kit - Replacing the HCI Pick Rollers

Open the HCI door, press the HCI top button to lower the shelf, and then remove any
paper as shown in Figure 4-56. The printer must be powered on and the HCI must be
connected to the printer for the HCI top button to lower the shelf.

LTR

Figure 4-56 Opening the HCI

Locate the back of the HCI and carefully remove the retaining springs providing tension
to the lower roller assembly, as shown in Figure 4-57. Notice how these springs are
attached to the lower roller assembly.

Consumables

Figure 4-57 HCI Rear and Lower Roller Assembly Springs

Ordering and Replacing Consumables 4-43

HCI Pick Roller Kit - Replacing the HCI Pick Rollers

Locate the white plastic clip securing the lower roller shaft at the far end, shown in
Figure 4-58. Remove this plastic clip.

Figure 4-58 Removing Clip From Lower Roller Assembly

Grasp the lower roller assembly and slide the shaft to the side away from the retaining
clip. Once free, lower the assembly and set it aside.

Figure 4-59 Remove Lower Roller Assembly

4-44 Ordering and Replacing Consumables

HCI Pick Roller Kit - Replacing the HCI Pick Rollers

Move to the front of the HCI. Locate the upper roller assembly on the top underside of
the HCI, as shown in Figure 4-60. Hold this assembly up with your hand.

Figure 4-60 HCI interior and Upper Roller Assembly location

With your other hand, locate the two thumb screws on the back side of the HCI, as
shown in Figure 4-61. Remove these two screws (turn counterclockwise) and set them
aside.

Consumables

Figure 4-61 Unscrew Thumbscrews and remove

Ordering and Replacing Consumables 4-45

HCI Pick Roller Kit - Replacing the HCI Pick Rollers

From the front of the HCI, gently pull out the upper roller assembly, as shown in Figure
4-62. Slide the assembly a little to the right before bringing it out of the HCI.

Figure 4-62 Remove Upper Roller Assembly

New HCI Pick Roller Kit
Unpack the new HCI pick roller kit, shown in Figure 4-63.

Figure 4-63 HCI Roller Kit

4-46 Ordering and Replacing Consumables

HCI Pick Roller Kit - Replacing the HCI Pick Rollers

Installing the HCI Upper Pick Rollers
When you install a new HCI pick roller kit, the shaft on the upper roller assembly (left side)
goes into the hole. See Figure 4-64.

Figure 4-64 Shaft and hole location for HCI Upper Pick Roller Assembly

From the front of the HCI, gently guide the upper roller assembly into place, as shown in
Figure 4-65.

Consumables

Figure 4-65 Installing Upper Roller Assembly

Ordering and Replacing Consumables 4-47

HCI Pick Roller Kit - Replacing the HCI Pick Rollers

Once the upper roller assembly is in place, gently hold it up and push it slightly to the
left (to help the screws engage). See Figure 4-66.

Figure 4-66 Holding Upper Roller Assembly in place

With your other hand, place the thumbscrews removed previously into the holes on the
back side of the HCI (shown in Figure 4-67). To get the proper screw engagement, you
may need to push the upper roller assembly slightly to the left. If necessary, look
through the screw holes to judge if the hole is aligned correctly. Tighten the
thumbscrews clockwise until they are snug.

Figure 4-67 Installing Thumbscrews

4-48 Ordering and Replacing Consumables

HCI Pick Roller Kit - Replacing the HCI Pick Rollers

Installing the HCI Lower Pick Rollers
1.

Hold the lower roller assembly and slide the front (closest) shaft into the front metal
retaining clip. Slide the back shaft into the back retaining clip. See Figure 4-68.

Figure 4-68 Installing Lower Roller Assembly

Snap the white plastic clip into place. It fits over a groove on the back end of the shaft to
secure the lower rollers (See Figure 4-69.) If you don’t see this groove, the rollers may
not be completely seated all the way onto the shaft.

Consumables

Figure 4-69 Installing Clip onto Lower Roller Assembly

Ordering and Replacing Consumables 4-49

HCI Pick Roller Kit - Replacing the HCI Pick Rollers

On the back of the HCI, carefully extend and install each retaining spring to the lower
roller assembly. The retaining springs have a "holder" to pull on while extending the
spring. See Figure 4-70.

Figure 4-70 Installing Retaining Springs

Push the HCI against the printer to lock it into place. Add paper to the HCI and close the
HCI door, as shown in Figure 4-71.

LTR

Figure 4-71 Closing the HCI Door

5.
6.

Press Done on the Control Panel.
Perform the Paper Path Alignment procedure described in “Adjusting Paper Path
Alignment” on page 6-11.

4-50 Ordering and Replacing Consumables

Maintenance
Introduction
Cleaning the D640 is an important factor in assuring optimum print quality. There are two
cleaning routines to follow:
• a short weekly cleaning routine that removes paper dust and stray toner particles from the
exterior of the printer.
• a more thorough internal cleaning procedure that should be performed when you replace
the drum.

Weekly Cleaning
Investing just a few minutes on your D640’s maintenance each week ensures minimum
downtime and maintains high print quality. Make sure someone is responsible for printer
maintenance. Perform the maintenance tasks at the recommended intervals.
Use these tools for cleaning:
•
•
•
•

Cleaning cloths (supplied with the D640 printer)
Rags
Vacuum cleaner specially designed for picking up toner
Blower brush (supplied with the D640 printer)

Note

Turn the main power switch OFF before performing the weekly cleaning.

Caution Make sure that the toner vacuum is properly grounded before using it in the printer,
or the printer may sustain electrical damage. Refer to the vacuum’s operating manual.

Maintenance

5-1

Maintenance

Weekly Cleaning

Removing Stray Toner
During removal or replacement of various consumable parts, toner occasionally spills onto the
printer interior or exterior.
• Do not attempt to clean up spilled toner with water or any other fluid, as this can harm the
developer, toner, and printer mechanism.
• Use a vacuum cleaner especially designed for trapping toner particles. Regular vacuum
cleaners cannot trap the fine toner particles and will exhaust them back into the air. If you
are unsure which vacuum cleaner to use, consult your service representative.

Toner Hopper Area
To clean the toner hopper area, follow these steps:
1.
2.

Turn off the main power switch, and open the upper right cover.
Use the toner vacuum to remove any toner on the upper surface of the toner hopper. Use
the supplied cleaning cloths to wipe up any toner or dust off the outside of the toner
hopper area. Clean all the way across the toner hopper area, paying careful attention to
the area in and around the toner hopper. Figure 5-1 illustrates the cleaning procedure.

Figure 5-1

5-2

Cleaning Toner Hopper area

Close the upper right cover.

Maintenance

Precharger Area
The precharger is a wire located inside the drum. The drum contains a built-in cleaning rod to
remove toner that might build up on the precharger wire.
To clean the precharger, follow these steps:
1.

Pull out the precharger cleaner handle (Figure 5-2), then push it back into its original
location. Repeat this "out-in" process 4 or 5 times.
Precharger cleaner

Figure 5-2

Cleaning the Precharger

Push the precharger cleaner in completely.

Maintenance

5-3

Maintenance

Weekly Cleaning

Paper Feed Area
To clean the paper feed area, follow these steps:
1.
2.

Open the lower right cover.
Use the supplied cleaning cloths to wipe up any toner or dust off the paper feed
mechanisms in this area, on the inside area and on the cover area. Clean all the way
down to the base of the printer to ensure a thorough cleaning. See Figure 5-3.

Caution To avoid damage to the paper sensors in the paper feed area, wipe the area from
bottom to top.

Figure 5-3

Cleaning Paper Feed Area

Close the lower right cover.

Paper Input Trays
To clean the inside of the paper input trays, follow these steps:
1.
2.
3.
4.

5-4

Remove tray3 from the printer, then remove any paper in it.
Use the vacuum cleaner to remove any paper dust or chips from the tray.
Reinstall the paper in the tray, and the tray in the printer.
Repeat steps 1 - 3 for the other two trays.

Maintenance

Printer Exterior
1.
2.

Check the paper output tray on top of the printer and use the vacuum to remove any
paper dust or dirt.
Vacuum the area around the ventilation slots on the rear of the printer to remove any
dust accumulation.

Periodic Cleaning (When Replacing Drum)
Perform the following cleaning routine when you replace the drum assembly.

Reversing Unit Area
1.
2.
3.

Turn the main power switch off, and open the front door.
Hold lever 5 to the left to open the reversing unit area. See Figure 5-4.
Use the supplied cleaning cloths to wipe up any toner or dust off the reversing unit.
Clean all the accessible areas, working toward the back of the printer, to ensure a
thorough cleaning.

Figure 5-4

Cleaning Reversing area

Maintenance

5-5

Maintenance

Periodic Cleaning (When Replacing Drum)

Duplex Area
Caution As you clean the duplex unit, avoid wiping the paper sensor from right to left or
perpendicular to the paper feeding direction. Wipe the area from left to right.
1.

Raise lever 6 and use the supplied cleaning cloths to wipe up any toner or dust off the
duplex area in this area, wiping from left to right. Wipe all of the accessible area to
ensure a thorough cleaning. See Figure 5-5.

Figure 5-5

2.
3.

Cleaning Duplex Area

Lower lever 6 to close the duplex unit.
Wipe away any paper dust or toner on the upper surface of the duplex unit.

Transfer Assembly - Transfer LED Areas
To clean the transfer assembly:
1.

5-6

Use the supplied cleaning cloths or the vacuum cleaner to wipe any toner or dust off the
outside of the transfer guide and paper guides.
As you handle the transfer assembly, take care not to touch or damage the transfer wire.
Pull out gently on Handle 3 to unlatch and release the transfer guide. Gently lower the
transfer guide and let it rest on the bottom of the printer’s interior. See Figure 5-6.

Maintenance

Periodic Cleaning (When Replacing Drum)

Handle 3

Figure 5-6

Handle 3 and Transfer Assembly Guide

Push in and pull up on the transfer assembly to free it from the guide assembly, as shown
in Figure 5-7.
Transfer assembly guide
Transfer assembly

Transfer assembly guide

Transfer assembly

Wire

Figure 5-7

LTR

Removing the Transfer Assembly

Maintenance

5-7

Periodic Cleaning (When Replacing Drum)

Use the supplied blower brush, stored in a pocket inside the front door, to clean the
transfer assembly wire (see Figure 5-8.) Move the brush back and forth across the wires
while quickly squeezing the rubber handle. This blows air to help remove toner and
paper dust. Turn the transfer assembly over so the opposite side can be cleaned in the
same way, and do so. Set the transfer assembly aside in a safe location.

Figure 5-8

5-8

Cleaning the Transfer Assembly

Maintenance

Transfer Assembly Guide
To clean the Transfer Assembly Guide:
1.
2.

Take out the drum unit (refer to “Removing the Drum” on page 4-21.)
Use the supplied cleaning cloths or vacuum cleaner to wipe up any toner or dust off the
outside of the transfer assembly guide. Clean all the way to the back of this guide. See
Figure 5-9.

Figure 5-9

Cleaning Transfer Assembly Guide

Maintenance

5-9

Maintenance

Periodic Cleaning (When Replacing Drum)

LED Array Area
To clean the LED Array:
1.

Use the supplied cleaning cloths to wipe up any toner or dust off the outside of the LED
array. Clean all the way across the LED array. Figure 5-10 shows the LED array and
illustrates the cleaning procedure.

Caution Be careful to avoid contacting the developer unit roller on the right side of the area,
as this could damage the developer.

Figure 5-10 Cleaning LED Array

Install the new drum assembly, as described in “Drum Kit - Replacing Drum and
Transfer Assembly” on page 4-18.

5-10 Maintenance

Reinstalling the Transfer Assembly
1.

Using the alignment pin located on the end of the cleaned transfer assembly, insert the
alignment pin of the transfer assembly into the left rail of the transfer assembly guide
and push in to the end of the guide. See Figure 5-11.
Transfer assembly guide
Transfer assembly

Transfer assembly guide

Transfer assembly

Wire

LTR

Figure 5-11 Inserting the Transfer Assembly into the guide

Maintenance 5-11

Maintenance

Periodic Cleaning (When Replacing Drum)

Secure the transfer assembly by lifting Handle 3, as shown in Figure 5-12.

Handle 3
Transfer assembly
guide

LTR

Figure 5-12 Securing the Transfer Assembly

Close the front door.

Note If you have problems reinstalling the transfer assembly, check to see that the drum is
installed correctly.

5-12 Maintenance

6
Advanced Topics

Advanced Topics
This chapter presents information about:
•
•
•
•
•
•

Maintaining print quality
Managing consumables
Adjusting paper path alignment
Setting up edge-to-edge printing
Configuring for LaserJet compatibility
Using virtual font cartridges

The topics in this chapter help you find new uses for the printer, manage your consumable
supplies, and maintain optimum print quality.

Maintaining Print Quality
In some situations, print quality can be very subjective, and in other situations, the problem is
very obvious. This section provides guidelines for making correct diagnosis of the problem to
minimize incorrect and needless repairs.
Visual print quality analysis assumes you have maintained the printer according to the required
maintenance procedures and schedule. Chapter 5 provides the printer maintenance schedule
and procedures.
This section provides print samples, starting with a good quality print. The rest of the print
samples are flawed. The consumables that may be responsible for the flaws are included with
each sample, along with recommended corrective actions.

Print Quality Troubleshooting
If you are dissatisfied with the quality of your prints:
1.
2.
3.

Complete all of the weekly maintenance tasks (see “Weekly Cleaning” on page 5-1).
Clean your printer thoroughly (see “Periodic Cleaning (When Replacing Drum)” on
page 5-5).
Check the quality of your prints.

Advanced Topics

6-1

Maintaining Print Quality

If you are still dissatisfied with your print quality:
1.

2.
3.
4.
5.

Print several test pages of your typical work output and compare the print quality to the
samples.
The print samples provided here are generic, that is, they show specific problems. Your
own print samples are typical of your printout problems and so you must compare problem effects and not the actual print pattern.
Generate test prints to compare with the quality samples. (See Appendix E for more
information.)
Identify a print quality sample included in this section that has the same flaws as your
print test.
Review and complete the actions listed under the print sample in the order in which they
are listed, generating a print after you complete each action.
Check the print’s quality; if the flaw or flaws are still present, continue to the next action
in the list. If the flaws are repaired, you do not have to complete the remaining actions.

If you complete all the recommended actions, including changing consumables, and the print
quality doesn’t improve, you may need to call your service representative to resolve the
problem. Refer to “Where To Call For Help” on page F-1 for the telephone number of your
nearest Hewlett-Packard service representative. Be prepared to give the service representative
the error code and any messages that appear on the Control Panel to assist in troubleshooting.

Print Quality Problems
When you have any print quality problems, check the following items before starting your
troubleshooting:
1.
2.
3.
4.

5.
6.
7.

6-2

Check the Control Panel for any messages about consumables. If there is a “Consumable
at end life” message, replace the consumable and retest for print quality.
Check whether the paper being used meets Hewlett-Packard standards. (Refer to “Using
Paper” on page D-1.)
Check whether the paper is handled correctly (especially for creases or wrinkles).
Check whether the environment for the printer and the paper meets Hewlett-Packard
standards - especially for humidity. Refer to Table C-5, “Printer environmental
specifications”.
Check whether the rollers and the paper guides are clean (especially for scattered toner
or developer, accumulated paper powder and paper pieces).
Check the Economode setting; be sure it is OFF. (See “Economode” on page 2-17.)
Adjust the print density. (See “Density” on page 2-25.)

Advanced Topics

Maintaining Print Quality

Advanced Topics

Good Quality Print Sample

Figure 6-1

Good quality print sample

Advanced Topics

6-3

Maintaining Print Quality

Specific Print Quality Problems
All sample pages are shown in Letter size and portrait orientation. Similar problems may show
up on different paper edges, depending on the paper feed

Fading
If a white streak or a faded area appears on the page (in the
direction the paper passes through the printer):
• Check the Economode setting; be sure it is OFF. (See “Economode” on page 2-17.)
• The moisture content of the paper may be uneven, or there may
be moist spots on the paper. Print several dozen test pages with
paper from a newly-opened ream.
• The print density setting may be too light. Adjust the print density. (See “Density” on page 2-25.)
• Toner may be on the transfer charger or pre-charger corona
wires. Clean the printer’s transfer assembly unit and precharger. (See “Transfer Assembly Guide” on page 5-9.)
• Replace the developer in the printer with new developer. (See
“Replacing Developer” on page 4-9.)
• Replace the drum unit with a new one. (See “Drum Kit Replacing Drum and Transfer Assembly” on page 4-18.)
• If you still have this print quality problem, contact your authorized HP service representative.

Dropouts
If faded areas, generally rounded, occur randomly on the page:
• The moisture content of the paper may be uneven, or there may
be moist spots on the paper. Print several dozen test pages with
paper from a newly-opened ream.
• The paper lot is bad. The manufacturing process can cause
some areas to reject toner. Try paper from a different source.
• Clean the paper feed path and LED array as described in
“Weekly Cleaning” on page 5-1 and “Periodic Cleaning
(When Replacing Drum)” on page 5-5.
• Replace the developer unit with a new one. (See “Replacing
Developer” on page 4-9.)
• If you still have this print quality problem, contact your authorized HP service representative.

6-4

Advanced Topics

Maintaining Print Quality

Lines

• Toner may be on the transfer charger or pre-charger corona
wires. Clean the printer’s transfer assembly unit and precharger. (See “Transfer Assembly Guide” on page 5-9.)
• Replace the drum unit with a new one. (See “Drum Kit Replacing Drum and Transfer Assembly” on page 4-18.)
• If you still have this print quality problem, contact your authorized HP service representative.

Toner Smear
If toner smears appear on the leading edge (as is passes through
the printer) of the paper:
• Toner may be loose inside the printer’s paper path. Clean the
printer by following the instructions in “Periodic Cleaning
(When Replacing Drum)” on page 5-5.
• Replace the drum unit with a new one. (See “Drum Kit Replacing Drum and Transfer Assembly” on page 4-18.)
• If you still have this print quality problem, contact your authorized HP service representative.

Background Gray Toner Shading
If the amount of background toner shading becomes unacceptable:
• The print density setting may be too high. Adjust the print density (See “Density” on page 2-25.)
• Toner may be on the transfer charger or pre-charger corona
wires. Clean the printer’s transfer assembly unit and precharger. (See “Transfer Assembly - Transfer LED Areas” on
page 5-6.)
• Change the paper to a lighter basis weight.
• Check the printer’s environment; very humid conditions can
increase the amount of background shading.
• Replace old developer with fresh developer. (See “Replacing
Developer” on page 4-9.)
• Replace the drum unit with a new one. (See “Drum Kit Replacing Drum and Transfer Assembly” on page 4-18.)
• If you still have this print quality problem, contact your authorized HP service representative.

Advanced Topics

6-5

Advanced Topics

If sharp or smeared black streaks appear on the page (in the
direction the paper passes through the printer):

Managing Consumables

Repetitive Defects
Repetitive marks appear repeatedly on the printed side of the
page.
• Replace the drum unit in the printer with a new drum unit. (See
“Drum Kit - Replacing Drum and Transfer Assembly” on
page 4-18.)
• Replace the fuser unit in the printer with a new fuser unit. (See
“Fuser Kit - Replacing the Fuser” on page 4-29.)
• If you are still having this print quality problem, contact your
authorized HP service representative.

Managing Consumables
Use the following checklist to identify actions you can take to maximize consumable yields.
Further detailed information is provided later in this section.
1.
2.

4.
5.
6.

7.
8.

6-6

Keep the printer clean. Follow all the maintenance procedures listed in Chapter 5.
Accumulations of toner and paper dust affect the yields of all consumables.
Use high-quality media. Factors such as paper chemicals or scratches from unsupported
media can damage the drum and fuser. See Appendix A for a description of supported
media.
Handle all consumables and print media with care. Protect the drum from light and
abrasion. Avoid dropping or rough handling of consumables after they are removed
from their cartons. Store the consumables and media in a clean, stable environment,
preferably at the same location or under the same environmental conditions as the
printer.
Use the toner management features discussed on page 6-7. The D640 printer supports
several features that maximize toner usage.
Monitor and, if possible, manage print job sizes. Single-page print jobs are the least
efficient for consumable usage. Longer, multiple-page jobs are more efficient.
Monitor and, if possible, manage the complexity of printed images. Images which are
too complex to print at rated speed (for example, a large, complex PostScript image)
reduce the life of the drum and developer. Also, printing repetitive images can wear the
fuser rollers unevenly.
Avoid frequent lapses into power save mode or frequent power cycling. The start-up
process uses some of the life of the drum and developer.
Avoid prolonged periods of inactivity with the power switched on. Hewlett-Packard
recommends you switch off printers that are inactive overnight if the power save feature
isn’t used.

Advanced Topics

Managing Consumables

Toner
Toner yields are primarily driven by the quantity of toner applied to each page. Large black
areas, graphic images, gray backgrounds and forms outlines use more toner. If you print
mostly or only a small amount of text, you will probably reach or exceed the estimated yield.
Toner yield estimates are based on 4% toner coverage. This is a standard value used by the
printer industry, which is based on the assumption that the "typical" A4 or letter-size business
letter is 4% covered by black area.
The D640 offers a number of features that, with some trade-offs, can extend toner yield.

Density
The density value is factory set to 10, approximately in the middle of its range. The density
value can be set as low as 1 to reduce toner consumption. To the naked eye, solid area patterns
will not appear any lighter under lower settings. Reducing the density will have the largest
visual effect on gray scale patterns or the small text characters.
Experiment to see if a lower density value can satisfy your print quality requirements. Actual
toner savings will vary based on the types of images printed. The density setting can be found
under the Maintenance Menu, described in “Density” on page 2-25.

Economode
Most printers simply print a lighter pattern when an economode setting is used. However, the
D640 does not lighten the entire image. Instead, dots are turned off in strategic areas to reduce
toner use while maintaining readability. When printing text in economode, the character
outline is perfectly formed, while the inside uses fewer dots. The effects are nearly invisible to
the naked eye at a 10 point character size, but may be more readily seen on large characters.
Experiment to see if economode can be used for some, if not all of your printing. Large textonly reports may be able to use economode with no perceptible reduction in print quality.
Economode can reduce toner consumption as much as 50%, depending on the printing pattern.
The Economode setting can be found under the Configuration Menu, described in
“Economode” on page 2-17.

Advanced Topics

6-7

Advanced Topics

Note The factory yield estimates for consumables are determined under operating
conditions which are intended to model a large sample of customer installations. However, it is
impossible to model every operating environment, and as result some installations may
experience lower consumable yields than expected. Keep a log of actual consumable usage for
each printer. This provides the most accurate data to plan consumable purchases.

Managing Consumables

Recycling
Printers that user powdered toner generally only transfer about 70 to 80% of the toner used for
a page image to the paper. The remaining 20 to 30% is known as waste toner because in most
printers it is thrown away. In a printer that uses a toner cartridge, the waste toner is never seen
because it is moved to a waste area inside the print cartridge.
The D640 printer is unique in the industry, providing the choice of recycling the waste toner or
throwing it away. As the printer ships from the factory, the toner recycling mode is disabled
and waste toner collects in a bottle. You remove and throw out this bottle each time you add a
new bottle of toner. With toner recycling enabled, the waste toner is funneled back into the
toner hopper and gradually mixed with new toner.
The disadvantage to recycling toner is a possible slight reduction in print quality. Print may
appear lighter and small voids may be visible in dark images. In most text applications, you
will probably not notice any reduced print quality with recycling on. If your application
requires the best possible print quality, do not use toner recycling.
Unlike Density and Economode, the effects of toner recycling are not immediately noticeable
when you stop recycling. The waste toner must be completely flushed from the toner path.
Depending on how long the recycling feature was used, it might take up to five bottles of new
toner before the waste toner is completely flushed from the system.

Toner Recycling Switch
Toner recycling is enabled or disabled by moving the plastic slide switch located directly over
the toner collector bottle. When it is pushed to the right, toner is recycled. When it is pushed to
the left, waste toner collects in the toner collector bottle for disposal. Figure 6-2 shows the
bottle and switch location.

6-8

Advanced Topics

Managing Consumables

Advanced Topics

Toner Recycle Slide

Figure 6-2

Toner Recycling Slide Switch

Drum and Developer
The drum and developer are grouped together because their yields depend on drum rotations.
There is physical wear on the drum and developer mixture with every rotation of the drum.
The drum is often rotating even when the printer is not printing. Factory yield estimates for the
drum and developer, listed on the data sheet and in this manual, can never be accurate because
there is not a one-to-one correspondence between drum rotations and printed pages. However,
the internal counters in the printer do count drum rotations for both the drum and developer.
The drum life is estimated at 250,000 drum rotations and the developer life is estimated at
160,000 drum rotations.
The drum rotates during power up, at the start and end of each job, and while printing each
image. Knowing what factors drive drum rotations helps you understand what determines the
lives of your drum and developer.
Frequent power cycling or lapses into power save mode add wear to the drum and developer.
During power-up or coming out of power save mode, the drum rotates for up to two minutes.
This can produce as many as 80 drum rotations even though no pages are printed.

Advanced Topics

6-9

Managing Consumables

The average number of pages in print jobs has a large effect on drum and developer life. Extra
drum rotations occur at the start and end of each job. There are four rotations at the beginning
and four rotations at the end. If the D640 primarily prints very small jobs (less than 25 pages),
you get lower than rated yields on the drum and developer. If you primarily print jobs larger
than 25 pages, you get higher than expected yields.
There is also a negative effect on drum rotations if you print complex images that slow the
printer down. If the printer controller cannot process the incoming data fast enough to keep the
printer running at 40 pages per minute, extra drum rotations occur for the print job.
The estimated yields for the drum and developer assume a job size of 25 page sides per job. It
is not important if you occasionally print small jobs or complex images; it’s important how
your print environment averages usage over a long period of time.
The drum surface is easily damaged by scratches, long exposure to fluorescent light (30
minutes), or exposure to direct sunlight (which may cause gray background shading). The
estimated yields do not account for replacement due to these factors.
Scratches can occur from unsupported media and may be significant enough to require the
drum to be replaced prior to the printer indicating the drum has reached its end of life.
Paper which emits certain chemicals or large amounts of paper dust can cause excessive drum
wear. If you this problem, contact your service representative or the paper manufacturer.

Fuser
The fuser yield is controlled by the number of times a letter or A4 sheet of paper passes
through it. The printer maintains a counter which increments based on the size of paper used.
Factors which may reduce fuser life can be related to printing repetitious images, media
problems or not replacing the cleaning roller when necessary.
Hewlett-Packard recommends mixing up the types and positions of print images printed
among print jobs. Fuser rollers can wear unevenly when a dark image, such as a company logo
or a thick dark line, is printed repeatedly in the same position on every page of every print job.
Media can also have an effect on fuser life. Paper which emits certain chemicals or large
amounts of paper dust can cause excessive wear. If you suspect problems of this sort, contact
your service representative or the paper manufacturer.
For optimum fuser life, replace the cleaning roller after every other bottle of toner, and follow
the recommended cleaning procedures in “Duplex Area” on page 5-6. The cleaning roller
deposits silicon oil onto the fuser roller surface to prevent toner from sticking. It also cleans
away small amounts of toner that adhere to the fuser roller surface. Failure to replace the
cleaning roller at the specified times can greatly reduce fuser yields.

6-10 Advanced Topics

Adjusting Paper Path Alignment

Ozone Filter
The ozone filter is replaced after every two bottles of developer. If replaced as specified, you
should always receive the specified yield.

The transfer unit is replaced whenever the drum is replaced. Care must be taken to prevent
accidental breakage of the delicate wires located inside the transfer unit. Unless physically
damaged, you will always receive the specified yield.

Pushing Consumable Life Beyond Estimated Yields
The printer maintains counters to track all consumable use and provides an alert message to
inform you when a consumable item needs to be replaced. The printer will not stop, except
for lack of toner or developer, but the message remains until you replace the specified
consumable. There is a built-in "grace period", so the message to replace a consumable
should occur long before you see any print quality or paper jam problems.
When you get a "Toner Low" or "Developer end-life" message, it is best to add toner or
developer as soon as possible. If toner runs out completely, or the developer reaches its endlife, the printer stops printing to prevent damage to the print engine.
Toner and developer are the only consumables for which the printer physically stops. If you
have a carefully monitored environment, you can watch the print quality and change the
consumables (other than toner and developer) only when absolutely necessary. This tactic may
further extend the replacement cycles of your consumables at your own risk.

Adjusting Paper Path Alignment
Over time, the paper path alignment may change slightly from the factory-set position. The
following paper path alignment procedure will set the printing alignment for each tray to
ensure correct print position. This procedure looks complicated, but after you have performed
it a once or twice, it should only take a few minutes to complete. It may need to be repeated
periodically to ensure proper alignment, but if you only print on blank paper, alignment is
usually not critical.
This procedure sets alignment for both simplex and duplex pages. If you have an HCI installed,
you can also set alignment for it.
Before proceeding, make sure that there is adequate (20 - 30 sheets) paper in each tray and the
HCI (if installed). This amount is necessary for accurate feeding.
Note Please read through the entire procedure before performing any of the
steps.

Advanced Topics 6-11

Advanced Topics

Transfer Unit

Adjusting Paper Path Alignment

This procedure includes the following tasks:
• Printing alignment sheets. When you run the alignment program from the printer’s hard
drive, the printer produces a set of alignment pages.
• Measuring alignment. By measuring the current alignment for each tray against a
reference standard, you simply add two numbers to determine new alignment values.
• Setting alignment values. Once you have determined new values, enter them in the
Control Panel and recheck the alignment.

Printing Alignment Sheets
1.
2.

Verify that all three paper trays and the HCI (if installed) have Letter (or A4) size paper.
Press the Test button on the Main Screen, shown in Figure 6-3.

Ready - - free
JUN 18 05:32.23
PCL

600dpi
LTR
LTR
LTR

Online
Offline
Offline
Figure 6-3

Custom

Test

LTR
PapSize

Main Screen

Use N to scroll down and highlight filesC, as shown in Figure 6-4, and press Select.

Test

Online
Online
Figure 6-4

Test Submenu

6-12 Advanced Topics

filesA
filesC

Select

Adjusting Paper Path Alignment
From the filesC submenu shown in Figure 6-5, use N to highlight USER_ADJ, then
press Select.

C:\

Online

dir
USER_ADJ\
PCLS\
PS\
MAINT\
FONTS\

Online
Figure 6-5

Select

FilesC submenu

Use N to highlight ALIGNSET.*, then press Select.
The last two numbers refer to the program version number, which may be different from
the version number shown in these illustrations. See Figure 6-6.

C:\USER_ADJ\

dir
ALIGNSET.12

Online
Online
Figure 6-6

Select

ALIGNSET.12

Advanced Topics 6-13

Advanced Topics

Adjusting Paper Path Alignment

The number 1 will appear in front of the ALIGNSET.* message, as shown in
Figure 6-7.

C:\USER_ADJ\

dir
1 ALIGNSET.12

Online
Online
Figure 6-7

Select

1 ALIGNSET.*

Press Online.

Note After pressing Online, there will be a few seconds delay as the printer loads the
program.
The printer then produces six sheets:
• a Simplex feed alignment ruler sheet. See Figure 6-8.
• a set of alignment sheets, one from each tray (and the HCI if it is installed.)
See Figure 6-9.
• a Duplex unit alignment ruler sheet, which measures the duplex sideways and lengthwise
alignment values (duplexv means "duplex vertical") See Figure 6-12.
The Simplex feed alignment ruler sheet contains:
• instructions for the alignment procedure
• a reference scale to measure the alignment sheets
• a workspace to calculate alignment values and adjustments
When the printer has finished printing these pages, you are ready to begin measuring the
alignment pages.

6-14 Advanced Topics

Adjusting Paper Path Alignment

Measuring Alignment
You will now read the adjustment values.
1.

Carefully and accurately, fold the top part of the Simplex feed alignment ruler sheet,
shown in Figure 6-8.

Advanced Topics

Adjustment scale
Fold line

Figure 6-8

Simplex Feed Alignment Ruler Sheet

Advanced Topics 6-15

Adjusting Paper Path Alignment

2.
3.

On the alignment sheet for tray 1, shown in Figure 6-9, locate the Feed 1 alignment
indicator line.
Place the simplex feed alignment ruler sheet adjustment scale between the ends of the
arrows (at "measure between these two arrows", shown in Figure 6-9).

Feed alignment indicator line

Feed 1: Upper tray
Direction of paper motion
Measure between these two arrows

Figure 6-9

Sample Alignment Sheet for Tray1

6-16 Advanced Topics

Adjusting Paper Path Alignment

Position the line labeled "Align with left edge of printed sheet" against the left edge of
the alignment sheet for tray 1. Figure 6-10 shows how the two sheets should look when
properly positioned.
The arrow printed on the alignment sheet for tray 1 will intersect the simplex feed
alignment ruler sheet scale at some value, as shown in the illustration.

Note Make sure that the tip of the arrow is on the exact edge of the paper. If it is not, your
measurement may be inaccurate.

Read measurement here

Feed alignment indicator line

Feed 1: Upper tray
Direction of paper motion

Place edge here

Measure between these two arrows

-25
-20
-15
-10
-5
0
+5
+10
+15
+20
+25

Align with left edge of printed sheet

Line on printed sheet indicates the required relative adjustment.

Direction of paper motion

Figure 6-10 Measuring alignment with alignment scale

Advanced Topics 6-17

Advanced Topics

Adjusting Paper Path Alignment

Record this value in the adjustment value area for tray 1 on the simplex feed alignment
ruler sheet. See Figure 6-11.

Example

-5

Original alignment value
currently in printer

Write in adjustment
value from line
measurement

-5

Figure 6-11 Original alignment value and adjustment value

Repeat steps 2 through 4 with the alignment sheets for trays 2, 3, and the HCI (if
installed).

Note The printer still prints a sheet for the HCI even if no HCI is present. Simply ignore this
page if you don’t have an HCI connected and paper installed in it.
8.

Now read the values for duplex pages as directed in the next section.

6-18 Advanced Topics

Adjusting Paper Path Alignment

Duplex (Double-Sided) Printing Alignment
Figure 6-12 illustrates the Duplex unit alignment ruler sheet, which provides a way to measure
the alignment between the printed image on the front and back sides of a double-sided page.

Advanced Topics

Lines printed on back side of sheet

Figure 6-12 Duplex Unit Alignment Ruler Sheet

On the duplex unit alignment ruler sheet, review each side of the paper. View through
the paper: hold the paper up to a bright light with the side with the alignment scale
facing towards you.
The sideways indicator line runs up and down the back of the page on the left. Look for
the indicator line and note where it crosses the scale on the left. Record this value on
sheet 1 at Duplex unit sideways alignment adjustment value.
The lengthwise indicator line runs across the back of the page. Look for the indicator
line and note where it crosses the scale in the middle of the page. Record this value on
sheet 1 at Duplex unit lengthwise alignment adjustment value.

Advanced Topics 6-19

Adjusting Paper Path Alignment

Setting Alignment Values
You will now calculate and enter the new alignment values into the Control Panel.
1.
2.

Calculate the new values.
For each adjustment value, add the two numbers and write the new value, as shown in
Figure 6-13. If the adjustment value you read off the sheet was 0, no new setting is
required for that tray.

-6
+8
+3
+15
-2
+14
-2
-2
0
+1
+7
+7

Figure 6-13 Adjustment values entered into work sheet

6-20 Advanced Topics

No adjustment necessary

Adjusting Paper Path Alignment

Printing
Configuration
PCL
Comms
Maintenance

Online
Online
Figure 6-14 Menu

From the Maintenance submenu shown in Figure 6-15, use N to highlight alignment and
press P.

Maintenance

Online

replace
alignment
density
= 10
testpages = 30
monitor
= OFF
date-time

Online
Figure 6-15 Maintenance submenu

Advanced Topics 6-21

Advanced Topics

3.
4.

Once you calculate the new value, enter it in the Control Panel as follows:
Press Menu on the Main Screen (see Figure 6-3).
Use N to highlight Maintenance, as shown in Figure 6-14, and press P.

Adjusting Paper Path Alignment

Select tray1 and press P. This is the Maintenance.alignment screen, shown in
Figure 6-16.

Maintenance.alignment

tray1
tray2
tray3
duplex
duplexv

=5
=6
=5
= -6
= -7

Online
Online

Figure 6-16 Maintenance.alignment Tray1 setting

Press either M or N to highlight the tray1 new value calculated on the Simplex feed
alignment ruler sheet. The selection range is from -25 to +25, (except for duplex
lengthwise, which is +7 to -7). See Figure 6-17.

Maintenance.alignment.tray1 =

Online
Online

5
6
7
8
9
10
Select

Figure 6-17 Tray1 values

8.
9.

Press Select to save the new value and to return to the Maintenance.alignment submenu.
Repeat steps 1 through 4 for trays 2, 3, HCI, duplex (duplex sideways), and duplexv
(duplex lengthwise).
10. Verify your alignment by repeating the procedure in “Printing Alignment Sheets” on
page 6-12. If the alignment is still off (plus or minus 3 to 4 increments or more), note
the adjustment values as you did in the previous alignment procedure, and set the new
adjustment values in the Control Panel.
Note

A 1 or 2 increment variation may remain after alignment; this is normal.

6-22 Advanced Topics

Setting Up Edge-to-Edge Printing

Note The print quality is not consistent within 1/6" of any edge. This is especially true for
the trailing edge of the second side in duplex printing. For this reason, Hewlett-Packard cannot
guarantee print quality within this 1/6" area. Your Hewlett-Packard warranty and service
contract does not cover service calls related to printing within this 1/6" area.
The quality and squareness of the paper determine print quality when printing close to the
physical paper edge. In general, you may experience degraded print quality within .25 inches
of any paper edge. When printing in duplex you may need to compensate for shrinkage and
curl that may occur when the first side is printed. Lighter weight and recycled papers tend to
shrink more then heavier weight papers.
If you define text to start printing at location 0,0 it will print outside the logical page. This may
or may not be on the physical page. Figure 6-18 describes the physical and logical page
formats.

Figure 6-18 Physical and Logical Page formats

Advanced Topics 6-23

Advanced Topics

The D640 printer ordinarily enforces a 1/6" unprintable area around the edge of any page. This
is the factory default and produces the best looking output. There may be some cases where
you don’t want this border. The D640 supports edge-to-edge printing, which allows you to
extend printing to the edge of the physical page.

Configuring for LaserJet IIIsi and 4si Compatibility

Configuring for LaserJet IIIsi and 4si Compatibility
The D640 printer is unique and different from the Hewlett-Packard LaserJet family of printers
in general, and from the LaserJet "si" series in particular. While these two printer families
share the same printer language (PCL and PJL), there are a number of physical differences to
their hardware.
We have included features in the D640 printer to make it behave like a LaserJet 4si, so your
print jobs turn out like you expect. In many instances these features also provide compatibility
with the LaserJet IIIsi and/or 5si.
This section covers the compatibility features associated with PCL commands.

Paper Input
The D640 has three paper input trays, while the LaserJet 4si has two. The LaserJet5si has
three.
HCI selection compatibility is provided through the HCI-Alias Control Panel setting. HCIAlias enables paper selection compatibility between a LaserJet IIIsi or 4si with an HCI and a
D640 with an HCI. You can also set HCI-Alias = HCI to pick paper from tray1, tray2, tray3, or
the HCI in response to the PCL commands shown in Table -6-1, “Paper tray map for HCIAlias = HCI”.

Example Configuration
LaserJet IIIsi / 4si
• UPPER TRAY contains paper for job separation.
• HCI TRAY contains white paper.
- This configuration provides 500 sheets in the upper tray and 1500 sheets in the HCI
tray. To match this configuration on the D640, set up the D640 as follows:
• TRAY1 contains paper for job separation.
• HCI contains white paper.
• Set HCI-Alias = tray2.
- This configuration provides 500 sheets in tray1 and 3000 sheets in the HCI. You could
also load paper for job separation in tray2 and tray3 to increase capacity to 1500 sheets.

6-24 Advanced Topics

Configuring for LaserJet IIIsi and 4si Compatibility

If HCI-Alias is set to HCI, the values shown below in Table -6-1, “Paper tray map for HCIAlias = HCI” are correct. If HCI-Alias is set to tray2, then you can send a job to either a 4si or
a D640.
Paper tray map for HCI-Alias = HCI

IIIsi, 4si

D640

5si

upper tray

upper tray (tray1)

upper drawer (tray2)

lower tray

middle tray (tray2)

lower drawer (tray3)

n/a

High Capacity Input

n/a

lower drawer (tray3)

fold out tray (tray1)

You can also set the default paper tray (used if there is no paper size or paper source command
embedded in the print job) from the Control Panel. Use the intray setting in the Printing Menu.

Using the LaserJet 5Si Driver
The D640 printer can be used with a LaserJet 5Si printer driver, but there are many differences.
For example:
• The input tray selection is different. See Table 6-1 above.
• The D640 printer does not support media type selection.
• The LaserJet 5Si does not support font cartridges.

Advanced Topics 6-25

Advanced Topics

Table 6-1

Using Virtual Font Cartridges

Using Virtual Font Cartridges
Each of the D640 internal fonts is almost identical to those used in the LaserJet 4si. Some
typefaces, treatments, and symbol sets are slightly different, due to advances in font
technology since the development of the 4si. For example, if you print a very large question
mark on each machine, you may notice differences in the shape.
All of the font sets from all of the 4si font cartridges sold by Hewlett-Packard are stored on the
D640’s internal hard disk drive as virtual font cartridges. You select the virtual font cartridge
by the Control Panel vcartridge1 and vcartridge2 settings (see “Virtual Font Cartridges” on
page 2-20). The font names are comparable to the actual physical cartridge.
Table 6-2

Virtual Font Cartridges

Typeface and Treatment

IIISi

4si

C40D

D640

Line Printer Med.

bitmap

Courier Med., Italic, Bold, Bold Italic

bitmap

Intellifont

Letter Gothic Med., Italic, Bold

Intellifont

Arial Med., Italic, Bold, Bold Italic

TrueType

Symbol Med.

TrueType

Times New Roman Med., Italic, Bold, Bold Italic

TrueType

Wingdings Med.

TrueType

Albertus ExtraBold

Intellifont

Albertus Med.

Intellifont

Antique Olive Med., Italic, Bold

Intellifont

CG Omega Med., Italic, Bold, Bold Italic

Intellifont

CG Times Med., Italic, Bold, Bold Italic

Intellifont

Clarendon Condensed Bold
Coronet

Intellifont

Garamond Antiqua

Intellifont

Garamond Halbfett

Intellifont

Garamond Kursiv

Intellifont

Garamond Kursiv Halbfett

Intellifont

Marigold.

Intellifont

Univers Condensed Med., Italic, Bold, Bold Italic

Intellifont

Univers Med., Italic, Bold, Bold Italic

Intellifont

ITC Zapf Dingbats

Intellifont

nr 1

1. ITC Zapf Dingbats are available on the D640 Decorative Words I built-in cartridge.

6-26 Advanced Topics

A
Printer Messages
Printer Initialization Failure
1.
2.
3.
4.

The printer may self-diagnose the problem and display the message as shown in Figure
A-2, on page A-2.
Write down the error code and message that appears on the Control Panel.
Refer to “Call Engineer error messages and codes” on page A-9 to determine the meaning of the error code.
If the error code calls attention to a specific physical component or location on the
printer, check the area specified and correct the problem. If you can, print a test pattern,
described in “Maintaining Print Quality” on page 6-1.
If you cannot resolve the problem, call your service representative, or refer to “Where
To Call For Help” on page F-1 for the telephone number of your nearest
Hewlett-Packard service representative. Be prepared to give the service representative
the error code and any messages that appear on the Control Panel to assist in troubleshooting.

Printer Reset
You can reset the printer without powering it off and on. This may be necessary if the printer is
stopped and the Control Panel does not respond.

Printer Messages

A-1

Print Messages

In the unlikely event that the printer does not start correctly, follow these steps:

Printer Messages

To perform a printer reset, press function buttons 1, 3, and 5 (shown in Figure A-1 below) at
the same time and release them. If the display goes blank and then returns in a few seconds, the
reset worked. If the display does not go blank, then power off the printer by moving the main
power switch to the OFF position. Wait 20 seconds and power the printer on. See “Powering
On the Printer” on page 1-18 and Figure 1-10.

Figure A-1

Press buttons to reset

Printer Messages
This appendix provides information about messages displayed on the printer’s Control Panel.
There are several types of messages:

• Status messages are reports about what the printer is doing and do not require any action.
Table A-1 lists these messages.

• Warning messages notify you when the life of a consumable is nearly over. Replace the
•
•
•

A-2

consumable when convenient. Table A-2 lists these messages and directs you to the
replacement procedure in this manual.
Paper jam messages occur when paper jams while moving along the printer’s paper path.
Table A-3 lists these messages and directs you to the paper jam removal section in this
manual.
Error messages indicate conditions that stop or prevent printing until the error is
corrected. Table A-4 lists these messages and directs you to the replacement procedure in
this manual.
Call Engineer error messages indicate conditions that may require a service representative
to resolve. In some cases, you may be able to resolve these problems yourself, so refer to
Table A-5 to interpret these error messages. This table includes corrective actions for each
message.

Printer Messages

Status Messages

Status Messages
The following is a list of normal status messages that will appear from time to time as you use
the D640. These messages provide status only and do not require any action by the operator.
The intention of these messages is to provide current printer status.
Status messages

Message

Explanation

Printer Initializing

The printer is performing self-diagnostics.

Printer warming up

The printer is heating the fuser unit for operation.

Ready -- free

The printer is powered on and ready to use. No data has been received
by the printer yet.

Ready -- printing

The printer is currently feeding paper and physically imprinting the
image on the paper.

Ready -- waiting

The printer has received partial data and is waiting for the host send
additional data.

Ready -- imaging

The printer has received data and is building the page image.

Ready -- processing

The printer is receiving data from the host.

Error mask on

The printer is operating with an error condition disabled. This can only
be set or reset by your service representative.

Menu Locked

The menu has either been locked from a print job or the printer is
processing a job and menu changes cannot be made.

Printer Messages

A-3

Print Messages

Table A-1

Warning Messages

Warning Messages
The following warning messages indicate conditions that require operator intervention, such as
when the output tray fills up with paper, or when a particular consumable has reached the end
of its life. The "end life" message remains until you replace the consumable. Always replace
the consumable as soon as possible to maintain the best print quality.
Caution If you ignore the "Toner low" message, eventually the printer will shut down with
the "Toner empty" message to prevent mechanical damage.

Caution If you ignore the "Developer end-life" message, eventually the printer will shut
down with the "Developer end-life/Change developer at once" message to prevent mechanical
damage.
Table A-2

Warning messages
Message

Explanation

Action

Output tray full

The printer’s output tray is full.

Remove paper from tray.

Paper-size mismatch

The requested paper size is not
available.

Load correct paper size.

Toner low

The supply of toner in the toner
hopper is low.

Add toner. See “Replacing
Developer” on page 4-9.

Developer end-life

The developer has reached the end
of its useful life and needs
replacement.

Replace developer. See
“Discharging Developer” on
page 4-9.

Drum end-life
(drum area blinks)

The drum has reached the end of
its useful life and needs
replacement.

See “Drum Kit - Replacing Drum
and Transfer Assembly” on
page 4-18.

Fuser end-life
(fuser area blinks)

The fuser has reached the end of
its useful life and needs
replacement.

See “Removing the Fuser” on
page 4-30.

Tray 1 rollers end-life

The indicated pick roller has
reached the end of its useful life
and needs replacement.

See “Printer Pick Roller Kit Replacing the Tray Pick Rollers”
on page 4-33.

The HCI pick rollers have reached
the end of its useful life and need
replacement.

See “HCI Pick Roller Kit Replacing the HCI Pick Rollers”
on page 4-42.

Tray 2 rollers end-life
Tray 3 rollers end-life
HCI rollers end-life

A-4

Printer Messages

Paper Jam Messages

Paper Jam Messages
Paper jam messages appear when there is a problem moving paper through the printer. One or
more sheets of paper may be jammed. Refer to the Control Panel’s indication of the jam
location and check Table A-3 below. If the jam message does not go away after removing the
jammed paper, check the area again for stray paper fragments, and check the Control Panel.
There may be more paper jammed at other locations in the paper path.
WARNING! When you remove jammed paper, avoid contact with the paper sensors in the
paper feed path. These small black plastic actuator levers are easily damaged.
Table A-3

Paper jams and their remedies

Paper Jam Messages

Refer to
page

Remedy

TRAY1 pick error Remove tray (1, 2, or 3), remove paper jam from paper entry
TRAY2 pick error area and/or within the tray.
TRAY3 pick error

page 3-24

Feed path jam 1 Open the front door, lower transfer assembly, rotate knob 1

page 3-26

counterclockwise and knob 2 clockwise to free paper,
remove jammed paper.

Feed path jam 2 Open the lower right cover, remove jammed paper.

page 3-26

HCI jam 1 Open HCI, lower paper, remove jammed paper.

page 3-32

HCI jam 2 Pull HCI away from printer, remove jammed paper.

page 3-34

HCI jam 3 Pull HCI away from printer, remove jammed paper.

page 3-34

HCI jam 4 Open the front door, lower transfer assembly, rotate knob 1

page 3-26

counterclockwise and knob 2 clockwise to free paper,
remove jammed paper.
Paper Path Jams

Fusing unit jam 1 Open the front door, lower transfer assembly, open lever 4,
Fusing unit jam 2 push decurler lever down, remove jammed paper to right.

page 3-36

Duplex path jam 1 Open the front door, raise lever 6, and remove jammed
Duplex path jam 2 paper. You may need to turn duplex roller knob to release

page 3-38

Print unit path jam (Reversing unit area jam)

page 3-40

the paper.

Open the front door, open lever 4, hold lever 5 away from
the fuser, and remove jammed paper. You may need to turn
duplex roller knob to release the paper.

Printer Messages

A-5

Print Messages

Loading Jams

Paper Jam Messages

Remedy

Refer to
page

Paper Ejection Jams

A-6

Ejection unit jam 1 Raise the paper ejection cover and remove jammed paper.
Ejection unit jam 2

page 3-43

HCO jam 1 Open the HCO door, rotate roller knob 1 to free paper, then
HCO jam 2 lift levers to remove paper.

page 3-45

Printer Messages

Error Messages

Error Messages
When any of the following error messages appear on the first line of the display screen, the
printer suspends printing until the error is corrected.
Error messages
Message

Explanation

Action

Ejection unit cover open

The ejection unit cover (on top
of the printer) is open or not
completely closed.

Close the ejection cover until it
clicks shut.

Front Door open

The front door is open or not
completely closed.

Close the front door until it latches.

Upper right cover open

The upper right cover is open or
not completely closed.

Close the upper right cover until it
latches.

Lower right cover open

The lower right cover is open or
not completely closed.

Close the lower right cover until it
latches.

HCI cover open

The HCI door is open or not
completely closed.

Close the HCI door until it latches.

Fuser interlock

The fuser is not seated
properly.

Remove and reinsert the fuser into
the printer. See “Removing the
Fuser” on page 4-30.

Drum unit interlock

The drum is not seated
properly.

Remove and reinsert the drum into
the printer. See “Removing the
Drum” on page 4-21.

Developer collector not in
(During developer replacement
only)

The developer collector bottle is
not seated properly or is
missing.

Remove and reinsert the developer
collector bottle into the printer. See
“Installing Developer Collector
Bottle” on page 4-16.

Toner empty

The toner hopper is out of
toner.

Refer to “Replacing Toner” on page
4-4 and install toner.

Printer Messages

A-7

Print Messages

Table A-4

Call Engineer Error Messages and Codes

Call Engineer Error Messages and Codes
Call Engineer error messages stop the printer and take it Offline. Some of these errors can be
corrected by the user, but most require a visit from your service representative.
Blinking
Error code

High-voltage power supply alarm
Call Engineer (SVC 6F)
PCL
Offline
Offline
Clear
Figure A-2

LTR
LTR
LTR
Menu

End

Call Engineer (Service Representative)

Before calling the service representative, follow these steps:
1.
2.
3.
4.

A-8

Try clearing the error by pressing Clear.
If the error condition persists, look up the error in “Call Engineer error messages and
codes” on page A-9 and follow the instructions.
If the error condition persists, power the printer off and on to clear the error.
If the error condition persists, call your local service representative.

Printer Messages

Call Engineer Error Messages and Codes

Call Engineer error messages and codes

Error
Message

Code

Description

Action

Pick motor 1
alarm

SVC 08

The upper tray’s pick motor
(tray 1) did not work correctly
and may need to be
replaced.

Try clearing the error by pressing Clear. If
the error condition persists, call your local
service representative.

Pick motor 2
alarm

SVC 09

The middle tray’s pick motor
(tray 2) did not work correctly
and may need to be
replaced.

Try clearing the error by pressing Clear. If
the error condition persists, call your local
service representative

Pick motor 3
alarm

SVC 0A

The lower tray’s pick motor
(tray 3) did not work correctly
and may need to be
replaced.

Try clearing the error by pressing Clear. If
the error condition persists, call your local
service representative.

Switch-back
motor alarm

SVC 0B

The switch-back motor (just
left of the fuser) did not work
correctly and may need to be
replaced.

Try clearing the error by pressing Clear. If
the error condition persists, call your local
service representative.

Feed motor
alarm

SVC 0D

The feed motor (located on
the bottom) did not work
correctly and may need to be
replaced.

Try clearing the error by pressing Clear. If
the error condition persists, call your local
service representative.

Stacker select
alarm

SVC 0E

The solenoid switch in the
printer which controls paper
output going to the HCO did
not work correctly and may
need to be replaced.

Try clearing the error by pressing Clear. If
the error condition persists, call your local
service representative.

Duplex motor
alarm

SVC 0F

The duplex motor did not
work correctly and may need
to be replaced.

Try clearing the error by pressing Clear. If
the error condition persists, call your local
service representative.

Fuser alarm
(time-out)

SVC 27

The fuser unit did not heat-up
to the normal fuser
temperature within the
allotted warm up time.

Confirm that the voltage rating on the fuser
matches the voltage rating of the printer.
Verify that the fuser unit is correctly
installed and that all printer doors and
covers are closed, then press Clear. If the
error message persists, refer to “Removing
the Fuser” on page 4-30 and replace the
fuser. If this error code returns, call your
service representative.

Fuser
temperature
high alarm

SVC 28

The fuser unit temperature is
above a normal level.

Verify that the fuser unit is correctly
installed and that all printer doors and
covers are closed, then press Clear. If the
error message persists, refer to “Removing
the Fuser” on page 4-30 and replace the
fuser. If this error code returns, call your
service representative.

Printer Messages

A-9

Print Messages

Table A-5

Call Engineer Error Messages and Codes

Error
Message

Code

Description

Action

Fuser
temperature
low alarm

SVC 29

The fuser unit temperature is
below a normal level.

Verify that the fuser unit is correctly
installed and that all printer doors and
covers are closed. Press returns, call from
the front panel. If the error message
persists, refer to “Removing the Fuser” on
page 4-30 and replace the fuser. If this error
code returns, call your service
representative.

Toner motor
alarm

SVC 50

The motor which drops toner
into the printer is not working
correctly and may need to be
replaced.

Open the upper right cover and check that
the connector at the right side of the toner
hopper is connected. If it is connected
properly, call your service representative.

Toner screw
rotation alarm

SVC 51

The waste toner auger is not
working correctly and may
need to be replaced.

To fix this error call your service
representative.

Developer
discharge
alarm

SVC52

During the developer
replacement procedure the
old developer might not be
evacuated properly. The
problem could be mechanical
or electrical.

To fix this error, call your service
representative.

Developer
shutter alarm

SVC54

During the developer
replacement procedure, the
shutter releasing the old
developer did not open
correctly. The problem could
be mechanical or electrical.

To fix this error, call your service
representative.

Toner autoadjustment
alarm

SVC 56

After the developer was
replaced, the automatic toner
calibration could not be done
correctly. The problem could
be mechanical or electrical.

Purge developer and try again with a new
bottle. If this error code persists, call your
service representative.

Toner density
high alarm

SVC 57

The concentration of toner in
the developer unit is above
the normal range.

Purge developer and try again with a new
bottle. If this error code persists, call your
service representative.

Toner density
low alarm

SVC 58

The concentration of toner in
the developer unit is below
the normal range.

Purge developer and try again with a new
bottle. If this error code persists, call your
service representative.

Toner density
voltage high
alarm

SVC 59

The reference voltage used
to measure the toner
concentration in the
developer unit is above the
normal range.

Purge developer and try again with a new
bottle. If this error code persists, call your
service representative.

A-10 Printer Messages

Call Engineer Error Messages and Codes

Code

Description

Action

Toner density
voltage low
alarm

SVC 5A

The reference voltage used
to measure the toner
concentration in the
developer unit is below the
normal range.

Purge developer and try again with a new
bottle. If this error code persists, call your
service representative.

Toner hopper
alarm

SVC 5B

The hopper which holds the
toner is not working correctly,
or there is no toner in the
hopper. This error will occur
if you continue to clear a
Toner Empty condition.

Confirm that the plastic protective cover on
the right side of the toner hopper was
removed (see page 2-47 of the D640
Installation Manual). If you have recently
added toner, call your service
representative. If you have not recently
added toner, try adding toner. If the toner
hopper is full, call your service
representative. If the toner hopper was
empty, cycle power after adding toner.

Main motor
alarm

SVC 69

The main motor did not reach
normal rotation speed.

Verify that the drum and fuser unit is
correctly installed and that all printer doors
and covers are closed, then press Clear. If
this error code returns, call your service
representative.

High-voltage
power supply
alarm

SVC 6F

The high voltage power
supply is not working
correctly.

Clean the transfer assembly charger (see
“Transfer Assembly Guide” on page 5-9)
and try to print again. If the error persists,
try replacing the transfer unit (see
“Removing the Transfer Assembly” on page
4-19). If the error still persists, try replacing
the drum unit (see “Drum Kit - Replacing
Drum and Transfer Assembly” on page 418). If the error persists after replacing the
drum unit, call your service representative.

Spindle motor
alarm

SVC 79

The motor inside the optical
unit did not reach the normal
rotation speed.

Turn the printer off for at least 30 seconds,
and turn the printer on again. If this error
code returns, call your service
representative.

BD1 alarm

SVC 7A

The BD (beam detection)
signal number 1, inside the
optical unit is not working
correctly.

Turn the printer off for at least 30 seconds,
and turn the printer on again. If this error
code returns, call your service
representative.

BD2 alarm

SVC 7B

The BD (beam detection)
signal number 2, inside the
optical unit is not working
correctly.

Turn the printer off for at least 30 seconds,
and turn the printer on again. If this error
code returns, call your service
representative.

BD speed high
alarm

SVC 7C

The BD (beam detection)
cycle, inside the optical unit
is above normal speed.

Turn the printer off for at least 30 seconds,
and turn the printer on again. If this error
code returns, call your service
representative.

Printer Messages A-11

Print Messages

Error
Message

Call Engineer Error Messages and Codes

Error
Message

Code

Description

Action

BD speed low
alarm

SVC 7D

The BD (beam detection)
cycle, inside the optical unit
is below normal speed.

Turn the printer off for at least 30 seconds,
and turn the printer on again. If this error
code returns, call your service
representative.

LD alarm

SVC 7E

The LD (laser diode), inside
the optical unit is not working
correctly.

Turn the printer off for at least 30 seconds,
and turn the printer on again. If this error
code returns, call your service
representative.

In-frame fan
alarm 1

SVC A0

Fan number 1 (inside the
optical unit) did not rotate
correctly.

Turn the printer off for at least 30 seconds,
and turn the printer on again. If this error
code returns, call your service
representative.

In-frame fan
alarm 2

SVC A1

Fan number 2 (upper left rear
side) did not rotate correctly.

Turn the printer off for at least 30 seconds,
and turn the printer on again. If this error
code returns, call your service
representative.

In-frame fan
alarm 6

SVC A3

Fan number 6 (fan for
cooling the main controller
board) did not rotate
correctly.

Turn the printer off for at least 30 seconds,
and turn the printer on again. If this error
code returns, call your service
representative.

In-frame fan
alarm 7

SVC A4

Fan number 7 (lower left rear
side) did not rotate correctly.

Turn the printer off for at least 30 seconds,
and turn the printer on again. If this error
code returns, call your service
representative.

Watchdog
timer alarm
(master)

SVC B0

The timer on the mechanism
controller board was not
reset by the “Master CPU”.
Turn the printer off for at
least 30 seconds, and turn
the printer on again. If this
error code returns, call your
service representative.

Turn the printer off for at least 30 seconds,
and turn the printer on again. If this error
code returns, call your service
representative.

Watchdog
timer alarm
(slave)

SVC B1

The timer on the mechanism
controller board was not
reset by the “Slave CPU”.
Turn the printer off for at
least 30 seconds, and turn
the printer on again. If this
error code returns, call your
service representative.

Turn the printer off for at least 30 seconds,
and turn the printer on again. If this error
code returns, call your service
representative.

Communicatio
n alarm

SVC B3

The communication
between the two processors
on the mechanism controller
board was disabled.

Turn the printer off for at least 30 seconds,
and turn the printer on again. This error is
not related to the serial or parallel ports. If
this error code returns, call your service
representative.

A-12 Printer Messages

Call Engineer Error Messages and Codes

Code

Description

Action

EEPROM
alarm

SVC B4

The mechanism controller
detected a problem with the
NVRAM (EEPROM).

Turn the printer off for at least 30 seconds,
and turn the printer on again. If this error
code returns, call your service
representative.

VS alarm

SVC B5

A return signal from the main
controller was not received
by the mechanism controller
during the normal response
time.

Turn the printer off for at least 30 seconds,
and turn the printer on again. If this error
code returns, call your service
representative.

Prepick alarm

SVC B6

A return signal from the main
controller was not received
by the mechanism controller
during the normal response
time.

Turn the printer off for at least 30 seconds,
and turn the printer on again. If this error
code returns, call your service
representative.

VR alarm
(time-out)

SVC B7

A return signal from the
mechanism controller was
not received during the
normal response time.

Turn the printer off for at least 30 seconds,
and turn the printer on again. If this error
code returns, call your service
representative.

HCI table
decent alarm

SVC C4

The HCI encountered an
error when the HCI’s table
was being lowered.

Refer to “Clearing HCI Jams” on page 3-32
to locate and remove any paper that may be
jammed inside the HCI. Look for any paper
stuck at the lower left side as you open the
HCI’s door. Reattach the HCI to the printer
and close the HCI’s door. Press Clear. If
this error code returns, call your service
representative.

HCI table
ascent alarm

SVC C5

The HCI encountered an
error when the HCI’s table
was being raised.

Refer to “Clearing HCI Jams” on page 3-32
to locate and remove any paper that may be
jammed inside the HCI, in particular look for
any paper stuck at the lower left side as you
open the HCI’s door. Reattach the HCI to
the printer and close the HCI’s door. Press
Clear. If this error code returns, call your
service representative.

HCO stacker
alarm

SVC D8

This code indicates an error
with the HCO.

Verify the following:
(1) the HCO interface cable is connected to
the printer, (2) the HCO’s power cable is
plugged into an working AC outlet, and (3)
the HCO’s power switch is turned on. (Refer
to the D640 Installation Manual for this
information). Press Clear. If this error code
returns, call your service representative.
Disconnect the HCO interface cable and
power the printer off and on to continue
using the printer without the HCO.

Printer Messages A-13

Print Messages

Error
Message

B
Host Serial and Parallel Interface Configuration
Introduction
The D640 printer is equipped with two standard communication interfaces used to connect to a
host computer:

• Bitronics (Parallel) interface
• RS-232C serial interface

Interface
Configuration

With the addition of an HP JetDirect EX interface, purchased separately, you can use the
printer on a local area network (LAN). The JetDirect EX interface connects the network to the
Bitronics interface of the printer. (If you purchased the HP JetDirect EX interface, you’ll find
detailed directions included in the JetDirect EX Configuration Guide.)

Parallel connector
Serial connector

Figure B-1

Standard Signal Interface Connectors

The standard parallel (IEEE 1284C) and serial (RS-232C) communication interface connectors
are located on the back of the printer, as shown in Figure B-1. The IEEE 1284C connector is at
the upper back of the printer; this connector is smaller than the usual (Centronics) parallel

Host Serial and Parallel Interface Configuration

B-1

Using the Serial Interface

connector. This is a “C” type Bitronics connection. Hewlett-Packard has included an “A-to-C”
parallel printer cable with the printer. The RS-232C connector is the standard DB25 pin
connector, located near the top center of the printer.
You can get more information about HP’s compliance with the IEEE 1284 Standard from the
HP FIRST fax retrieval service at 1-800-333-1917 in the USA and Canada. Ask for document
number 1951. The same document is also available by ftp from:
ftp://ftp-boi.external.hp.com/pub/printers/laserjet/doc/bp02455.asc

Using the Serial Interface
Use the serial interface when you need to locate the printer at some distance (up to 50 feet (15
meters)) from the host computer. You can use either an RS-232C or an RS-422A cable.
Table B-1 lists RS-232C and RS-422A pin assignments and signal descriptions. Those pins not
listed in the table are not used.
Table B-1

Pin assignments for a serial cable

Pin
Number

Description

RS-232
*

RS-422
*

I/O

Protective ground.

Transmitted data (data from printer).

n/a

Output

Received data (received by printer).

n/a

Input

3 (RS-422)

Received data inverted (RDA) (received by printer).

n/a

Input

Request to send. This signal is HIGH when the
printer is on.

n/a

Output

Signal ground.

9 (RS-422)

Send data inverted (SDA).

n/a

Output

10 (RS-422)

Send data non-inverted (SDB).

n/a

Output

Must be connected to ground (7) to select RS-422
mode (SDB).

n/a

Input

18 (RS-422)

Receive data non-inverted (RDB).

n/a

Input

Data terminal ready

n/a

Output

* = valid signal
n/a = unimplemented

B-2

Host Serial and Parallel Interface Configuration

Using the Serial Interface

The serial interface is accessible through a 25-pin female connector (Figure B-2) at the back of
the printer.
The interface can be configured to operate in an RS-232 or RS-422 configuration. Use the
control panel to set the configuration.
If you are set up for RS-232 operation, you can convert to RS-422 operation by shorting pin 14
of the interface to ground (pin 7).
(RS-232 interface)
1
2
3
4
5
6
Ground 7
8
9
10
11
12
13

Figure B-2

14
15
16
17
18
19
20
21
22
23
24
25

*422Sel

FGround
RxDA

DTR

Ground
TxDA
TxDB

1
2
3
4
5
6
7
8
9
10
11
12
13

14
15
16
17
18
19
20
21
22
23
24
25

*422Sel

RxDB

RS-232 and RS-422 Host Interface Connectors pin diagram

Interface
Configuration

FGround
TxD
RxD
RTS

(RS-422 interface)

Host Serial and Parallel Interface Configuration

B-3

Using the Parallel Interface

Using the Parallel Interface
The parallel interface uses a 36-pin connector (Figure B-3) at the back of the printer. It is an
IEEE 1284 Type C parallel connection.
Signal names on the following connector pin assignment diagram relate to Centronics
operating mode.

Busy
Select
Ack
Fault
P error
Data 1
Data 2
Data 3
Data 4
Data 5
Data 6
Data 7
Data 8
Init
Strobe
Select in
Auto Feed
NC

Figure B-3

B-4

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Peripheral logic hi

Parallel Host Interface Connector pin diagram

Host Serial and Parallel Interface Configuration

C
Specifications and Regulatory Information
Introduction
This chapter provides specifications, safety compliance, options, and printing paper for the
HP5000 family D640 cut sheet printer and accessories.
If you want to:
Printer specifications
Printable area specifications
Summary of printer options specifications
HCI specifications
HCO specifications
Custom tray specifications
Postscript upgrade
Safety information
Regulatory information
Safety standards
General considerations

page C-2
page C-6
page C-7
page C-7
page C-10
page C-12
page C-12
page C-13
page C-13
page C-15
page C-15

Specifications

•
•
•
•
•
•
•
•
•
•
•

Go to:

Specifications and Regulatory Information

C-1

Printer Specifications

Printer Specifications
This section provides general, print speed, physical, electrical, and environmental
specifications as well as safety standards.
Table C-1 lists general specifications for your D640 printer.
Table C-1

Printer general specifications

Item

Specifications

Printing
technology

Laser diode, electro-photographic

Printing speed

40 ppm (Letter and A4 landscape)

Paper

Size

Letter, Legal, Ledger. Executive, A3, A4, A5, B4 (JIS), B5 (JIS)

Type

Plain Paper, Label paper, Recycle paper, Transparency paper, Bond
paper, Pre-punched paper

Resolution

600 × 600 dpi

• 3 trays × 500 sheets (64 g/m2) standard
Paper capacity

• 1 tray x 500 sheets (64 g/m2) optional custom tray
• 3,000 sheets (A4, Letter size only) optional High Capacity Input
(HCI)

Stacker capacity

• 500 sheets (64 g/m2) face down tray
• 2,000 sheets optional High-Capacity Output

Emulation
Interface

PCL, HEX, optional PostScript (PS)
2 ports (Serial RS232C/422A and Parallel IEEE 1284C)

Warm-up time

Less than 150 seconds

First print time

Less than 18 seconds

Resident RAM

16 MB (Expandable to 64 MB)

Resident font

Bitmap font: 1, Outline fonts: 45

C-2

Specifications and Regulatory Information

Printer Specifications

Table C-2 lists D640 printer print speeds for various paper sizes.
Table C-2

Printer print speed specifications
From Tray 1, 2, 3
or HCI

Paper Size

Simplex

Duplex

Letter

Legal

Ledger

Executive

B4 (JIS)

B5 (JIS)

Custom (width = 120mm to 297mm,
length = 182mm to 215.9mm)

Custom (width = 120mm to 297mm,
length = 215.9mm to 431.8mm)

Notes:
1. Unit of measure: Images Per Minute (IPM)
2. In Simplex and Duplex Modes, all the speeds have ±5% tolerance.

Table C-3 lists the printer’s physical specifications.
Printer physical specifications

Item
Dimensions

Weight
Service area

Specification
Width

Depth

Height

570 mm (22.5 in)

630 mm (24.8 in)

1,030 mm (40.6 in)

Approximately 130 kg
Front

Back

Left

Right

650 mm (25.6 in)

850 mm (33.5 in)

Specifications and Regulatory Information

Specifications

Table C-3

C-3

Printer Specifications

Figure C-1 illustrates the physical specifications and Figure C-2 illustrates the required printer
service area dimensions.

40.5 in.
(1030 mm)
LTR

LTR

23.0 in.
(585 mm)

Figure C-1

C-4

1.38 in
(35 mm)

25.2 in.
(640 mm)

D640 Printer Physical Dimensions

Specifications and Regulatory Information

Printer Specifications

33.5 in.
(850 mm)
84.3 in.
(2140 mm)

33.5 in.
(850 mm)

Printer

25.2 in.
(640 mm)

Operating
Side

25.6 in.
(650 mm)

23.0 in.
(585 mm)

33.5 in.
(850 mm)

90.0 in.
(2285 mm)

Figure C-2

D640 Printer required service area dimensions

Table C-4

Printer electrical specifications
Item
Voltage

120 to 127 VAC ± 10%, 12A
200 to 240 VAC ± 10% 7A

Phase

Single-phase

Frequency

50/60Hz ± 5%

Power consumption

1,300 VA or less than during operating

Heat production

894 kcal per hour (3550 Btu per hour)

In-rush current

Up to 100 amps

Specifications

Input power

Specifications

Note If the printer is connected to a line conditioner, make sure the line conditioner can
support the in-rush current requirement for the printer.

Specifications and Regulatory Information

C-5

Printer Specifications
Table C-5

Printer environmental specifications
Item

Specification

Ambient Conditions

Operating

Temperature
Humidity

Maximum wetbulb temperature
Temperature and humidity gradients
Acoustic noise
Dust
Ozone emission

Non-operating

15 to 35°C

0 to 35°C

20 to 80% RH
(no condensation)
40 to 60% RH optimal

29°C (no condensation)
15 °C per hour or less and 30% RH per day or
less (no condensation)
See Table C-15 for details.
0.15 mg./m3 (stearic acid)
0.1 PPM or less

Best Printing Area Specifications
Place your printed image in an area within a 1/6 inch (4.23 mm) border. Printing outside of this
boundary may be of lower quality.
Figure C-3 shows the best printing area.

Margin

Best area

Figure C-3

Best printing area

If data is printed outside the best printing area, you may obtain poor print quality.

C-6

Specifications and Regulatory Information

D640 Optional Accessories

D640 Optional Accessories
Table C-6 lists printer options and their associated specifications.
Table C-6

D640 printer options and specifications summary
Item

Specification

Part Number
2

High-Capacity Input (HCI)

3,000 sheets (20 lbs; 64 g/m )

C5621A (Letter)
C5622A (A4)

High-Capacity Output (HCO)

2,000 sheets (20 lbs; 64 g/m2)

C5623A (120 V)
C5624A (200 - 240)

Custom paper tray

500 sheets (at 75g/m2)

C5634A

Standard paper tray

500 sheets (at 75g/m2

C5625A

PostScript upgrade

PostScript Level 2
(includes 16 MB memory)

C5630A

16 MB Memory Kit

16 MB SIMM (maximum 3 SIMMs)

C5635A

High Capacity Input (HCI) Specifications
The C5621A and C5622A are user-installable high capacity input (HCI) paper hoppers.
C5621A uses Letter size paper only and the C5622A uses A4 size paper only.
Figure C-4 illustrates the C5621A/C5622A high capacity input hopper.
11.3
in
(287 .
mm)

Printer

17.6
in
(446 .
mm)

Figure C-4

Specifications

22.2
in
(562 .
mm)

High Capacity Input physical dimensions

Specifications and Regulatory Information

C-7

High Capacity Input (HCI) Specifications

Table C-7 lists the HCI paper related specifications.
Table C-7

HCI paper handling specifications
Item

Specifications

Processing speed
Paper

40 ppm (C5621A: Letter landscape, C5622A: A4 landscape)

Size

C5621A: Letter / C5622A: A4

Type

Plain paper, Label paper, Bond paper, Pre-punched paper, 64 to 90g/m2

Paper capacity

3,000 sheets (75g/ m2)

Table C-8 lists the HCI physical dimensions, unit weight, and required service area dimensions
and Figure C-4 illustrates these dimensions. Figure C-5 illustrates the HCI service area
requirements.
Table C-8

HCI physical specifications

Item
Dimensions
Weight
Service area

C-8

Specification
Width

11.3 in (287 mm)

Depth

17.6 in (446 mm)

Height

22.2 in (562 mm)

About 38 lbs (17 kg)
Front

25.6 in (650 mm)

Back

33.5 in (850 mm)

Right

33.5 in (850 mm)

Specifications and Regulatory Information

High Capacity Input (HCI) Specifications

33.5 in.
(850 mm)
84.3 in.
(2140 mm)
HCO

Printer

HCI

25.6 in.
(650 mm)

Operating
Side

33.5 in.
(850 mm)

25.2 in.
(640 mm)

23.0 in.
(585 mm)

33.5 in.
(850 mm)
11.38 in.
(289 mm)

21.25 in.
(540 mm)
122.6 in.
(3114 mm)

Figure C-5

HCO (left), D640 Printer (center), and HCI (right) required service area
dimensions

HCI Electrical Specifications
Table C-9 lists the HCI electrical specifications.
HCI electrical specifications
Item
Input power
Power consumption

Specification
24VDC, supplied from D640 printer
30VA or less during operating

Specifications

Table C-9

Specifications and Regulatory Information

C-9

High Capacity Output (HCO) Specifications

High Capacity Output (HCO) Specifications
Figure C-6 shows the user-installable high capacity output (HCO). Model number C5623A is
the 120VAC version, and model number C5624A is the 240VAC version. The HCO can stack
up to 2000 sheets of paper.
16.1 in.
m)
(408 m

.
17.4 in
m)
m
2
4
(4

.
0 in
36. m)
3m
(91

Printer

Figure C-6

High Capacity Output physical dimensions

HCO Paper Handling Specifications
Table C-10 lists the HCO paper handling specifications.
Table C-10

HCO paper handling specifications
Item

Specifications

Processing speed

Paper

40 ppm

Size

Letter, Legal, Ledger, Executive, A3, A4, A5, B4(JIS),
B5(ISO)

Type

Plain paper, Label paper, Transparency, Bond paper,
Pre-punched paper, 64 to 90g/m2

Paper capacity

2,000 sheets (75g/ m2)

C-10 Specifications and Regulatory Information

High Capacity Output (HCO) Specifications

HCO Physical Specifications
Table C-11 lists the HCO physical dimensions, unit weight, and also provides the required
service access area dimensions.
Figure C-6 illustrates these specifications.
Table C-11

HCO physical specifications

Item

Specification

Dimensions

Width

16.1 in, 408 mm

Depth

17.4 in (446 mm)

Height

36.0 in, 913 mm

About 70 lbs (32 kg)

Weight

Front

Service area

25.6 in (650 mm)

Back

33.5 in (850 mm)

Right

33.5 in (850 mm)

HCO Electrical Specifications
Table C-12 lists the HCO electrical specifications.
Table C-12

HCO electrical specifications
Item
Voltage

100 to 120 VAC ± 10%,
200 to 240 VAC ± 10%

Phase

Single-phase

Frequency

Power consumption
Heat production

50/60Hz
120 VA or less than during operating
83 kcal per hour

Specifications

Input power

Specifications

Specifications and Regulatory Information C-11

Printer Custom Paper Tray Specifications

HCO Environmental Specifications
Table C-13 lists the HCO environmental specifications.
Table C-13

HCO environmental specifications

Ambient Condition

Operating

Temperature
Humidity

Temperature and
humidity gradients

Non-operating

15 to 35 °C

0 to 35 °C

20 to 80% RH
(no condensation)
40 to 60% RH optimal

15 °C per hour or less and 30% RH per day or less (no
condensation)

Printer Custom Paper Tray Specifications
The C5634A custom paper tray is a user-installable, optional paper tray compatible and
switchable with any of the standard printer paper trays. The custom paper tray can hold up to
500 sheets of paper, as listed in the Table C-14 specifications.
Table C-14

Custom paper tray physical specifications
Minimum

Maximum

Width

120 mm

297mm

Length

182 mm

431.8 mm

The paper guides in the custom paper tray are adjustable, and it also supports the following
standard media sizes: Letter, Legal, Ledger, Executive, A3, A4, A5, B4 and B5.

PostScript Upgrade
The C5630A PostScript upgrade is a user-installable optional upgrade for PostScript Level 2
emulation.
You can add PostScript to your D640 printer with the C5630A PostScript upgrade. If you add
PostScript, you must also install another 16 MB of printer memory (included with the C5630A
PostScript upgrade kit).

C-12 Specifications and Regulatory Information

Safety and Regulatory Information

Safety and Regulatory Information
This product was tested for conformance to various national and international regulations and
standards. The scope of this regulatory testing includes electrical and mechanical safety,
electromagnetic emissions, immunity, acoustics and hazardous materials.
When required, approvals are obtained from third party test agencies. Approval marks appear
on the product label. In addition, various regulatory bodies require some information under the
headings noted below.

FCC Statement (USA only)
This equipment has been tested and found to comply with the limits of a Class A digital device
pursuant to part 15 of FCC Rules. These limits are designed to provide reasonable protection
against harmful interference when the equipment is operated in a commercial environment.
This equipment generates, uses, and can radiate radio frequency energy, and if not installed
and used in accordance with the instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is likely to cause harmful
interference, in which case the user will be required to correct the interference at his own
expense.
Any changes or modifications not expressly approved by Hewlett-Packard could void the
user’s authority to operate this equipment.
Use of a shielded interface cable is required to comply within the Class A limits in part 15 of
the FCC rules.

DOC Statement (Canada only)
This Class A digital apparatus meets all the requirements of the Canadian Interference-Causing
Equipment Regulations.
Cet appareil numérique de la classe A respecte toutes les exigences du Règlement sur le
matériel brouilleur du Canada.

Europe RFI Statement

Specifications

This is a Class A product. In a domestic environment, this product may cause radio
interference, in which case the user may be required to take adequate measures.

Specifications and Regulatory Information C-13

Safety and Regulatory Information

Acoustics Emissions
Table C-15

Acoustic noise levels per ISO 9296, with HCI and HCO
Operation

Printer Only

With HCO
and HCI

Power Save
Mode

Bystander (while printing)

56 dB(A)

58 dB(A)

Bystander (in standby mode)

52 dB(A)

33 dB(A)

Sound Power (while printing)

7.4 bels(A)

7.7 bels(A)

Sound Power (in standby mode)

6.6 bels(A)

4.5 bels(A)

Data Communications (United Kingdom only)
Pursuant to Section 22 of Telecommunications Act of 1984, this product is approved for
indirect connection to Public Telecommunications systems within the United Kingdom under
the General Approval number NS/G/1234/J/100003.

Material Safety Data Sheets
Hewlett-Packard has Material Safety Data Sheets (MSDS) available for all chemicals
associated with the printing process implemented by all HP products. Should your site require
a Material Safety Data Sheet for an HP-supplied chemical in use at your site, please contact HP
at 1-800-752-0900 in the US (or 613-820-6483 in Canada) or your local HP service office, and
provide the following information:

•
•
•
•
•
•
•

HP part or product number
Chemical substance description
Your name
Company name
Company address
Telephone number
FAX number, if the request if for a FAX copy

C-14 Specifications and Regulatory Information

Safety Standards and General Considerations

EPA Energy Star Computer Compliance
Your D640 printer is designed to conserve electricity by dropping from 165W while printing to
under 45W when in the PowerSave mode. For maximum energy conservation, HewlettPackard recommends that the printer be turned off when it will not be used for more than a few
days. With this new, power-saving design, your D640 printer qualifies for the U.S.
Environmental Protection Agency’s Energy Star Computer compliance.
As an Energy Star partner,
Hewlett-Packard Company
has determined that this
product meets Energy Star
Guidelines for energy
efficiency.

Safety Standards and General Considerations
This printer has been designed to conform to recognized technical standards, including the
following national and international product safety standards and norms:

•
•
•
•
•

CSA C22.2 No. 950
EN 60950 (IEC 950)
EN 60825 (IEC 825)
UL 1950
U.S. CDRH 21CFR Ch.1 Subch J

Specifications

Any unauthorized removal of safety covers, manipulation of safety switches, and interference
with the safety system is strictly prohibited. Such actions can cause personal injury and can
damage the system. Also make sure that the operating and maintenance areas are not
obstructed in any way.

Specifications and Regulatory Information C-15

Laser Safety Standards

Laser Safety Standards
Printer Laser Equipment Compliance Label
This product is a Class I laser product.
The laser safety label is located on the top of the optical unit.
DANGER INVISIBLE LASER RADIATION WHEN OPEN AND INTERLOCK
FAILED OR DEFEATED.

AVOID DIRECT EXPOSURE TO BEAM
ATTENTION EXPOSITION AU LASER INVISIBLE SI OUVERT OU SI LE
VERROUILLADE EST DEFECTUEUX EVITER L’EXPOSITION DIRECTE
AU RAYON DE LASER.
VORSICHT UNSICHTBARE LASERSTRAHLUNG. WENN ABDECKUNG
GEOFFNET UND SICHERHEITSVERRIEGELUNG UBERBRuCKT NICHT
DEM STRAHL AUSSETZEN.
FARA Risk för stråining av osynilgt laserljus om såkerhetsorytare är ur funktion
då tuckan öppnas.

Laser Safety Statement (USA Only)
The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug
Administration has implemented regulations for laser products manufactured since August 1,
1976. Compliance is mandatory for products marketed in the United States. This printer is
certified as a “Class 1” laser product under the U.S. Department of Health and Human Services
(DHHS) Radiation Performance Standard according to the Radiation Control for Health and
Safety Act of 1968. Since radiation emitted inside this printer is completely confined within
protective housings and external covers, the laser beam cannot escape during any phase of
normal user operation.
Caution Use of controls or adjustments or performance of procedures other than those
specified herein may result in hazardous radiation exposure.

C-16 Specifications and Regulatory Information

Laser Safety Standards

Laser Safety Statement (Finland Only)

LASERTURVALLISUUS
LUOKAN 1 LASERLAITE
KLASS 1 LASER APPARAT
HP5000 D640 laserkirjoitin on käyttäjän kannalta turvallinen luokan 1 laserlaite. Normaalissa
käytössä kirjoittimen suojakotelointi estää lasersäteen pääsyn laitteen ulkopuolelle. Laitten
turvallisuusluokka on määritetty standardin EN 60825 (1991) mukaisesti.

VAROITUS !
Laitteen käyttäminen muulla kuin käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän
turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle.

VARNING !
Om apparaten används på annat sätt an i bruksanvisning specificerats, kan användaren utsättas
för osynlig laserstrålning, som överskrider gränsen för laserklass 1.

HUOLTO
HP 5000 D640 kirjoittimen sisällä ei ole käyttäjän huollettavissa olevia kohteita. Laitteen saa
avata ja huoltaa ainoastaan sen huoltamiseen koulutettu henkilö. Tällaiseksi
huoltotoimenpiteeksi ei katsota värianekasetin vaihtamista, paperiradan puhdistusta tai muita
käyttäjän käsikirjassa lueteltuja, käyttäjän tehäväksi tarkoitettuja ylläpitotoimia, jotka voidaan
suoritta ilman erikoistyökaluja.

VARO !
Mikäli kirjoittimen suojakotelo avataan, olet alttina näkymättömälle lasersäteilylle laitteen
ollessa toiminnassa. Älä katso säteeseen.

VARNING !
Om laserprinterns skyddshölje öppnas då apparaten är i funktion, utsättas användaren för
osynlig laserstrålning. Betrakta ej stralen.
Tiedot laitteessa käytettävän laserdiodin säteilyominaisuuksista:

Specifications

Aallonpituus 780 nm
Teho 5 mW
Luokan 3B laser

Specifications and Regulatory Information C-17

HP Declaration of Conformity

C-18 Specifications and Regulatory Information

Using Paper
The D640 prints on a variety of print media, including paper, labels, and overhead
transparencies, at up to 600 x 600 dots per inch (dpi).
Note

The D640 does not accept envelopes as print media.

The D640 printer uses laser electrophotographic technologies. In this process, a laser writes an
electrostatic image onto the photosensitive drum. As this image passes the developing station,
a dry, powdery toner is attracted to the imaged areas. This developed image then advances to
the transfer station, where the belt contacts the media and the toner image is electrostatically
transferred onto the paper. After transfer, the media passes through the fuser; heat and pressure
are applied and the toner fuses (melts) onto the media. The media is then deposited in the
output tray, ready for use.
To create the printed image all print media must be transported through the printer,
electrostatically charged, and heated. This is why media properties such as electrical
resistivity, caliper, smoothness, and stiffness can affect the print quality and media handling
performance of your D640 printer.

Supported Print Media Types
Your D640 printer will print on a variety of media, including paper, labels, and overhead
transparencies. “Media Selection Specifications and Guidelines” on page D-3 provides
suggestions for these different media.
Hewlett-Packard neither warrants nor recommends the use of a particular print media. Media
properties are subject to change by manufacturers and Hewlett-Packard has no control over
such changes. The customer assumes all responsibility for the quality and performance of
media. Although testing media helps to characterize their performance, long-term satisfaction
requires process quality control by the manufacturer and proper handling until use.

Alternate Sources of Information
The manufacturer and the vendor of the media that you select should be able to provide
information about the suitability of its use in a D640 printer. Your vendor should be your
contact when selecting media for your individual application needs. If you have tried all of the
suggestions outlined in this document, and still need assistance, HP provides support through
the world-wide network of Hewlett-Packard Sales and Service Offices. Refer to “Warranty and
Support” on page F-1.
Using Paper

D-1

Using Paper

Paper Manufacturing

In the United States, Hewlett-Packard also offers support through a local support
representative. A customer support technician will be happy to offer advice to help solve your
printer operation problems.

Paper Manufacturing
Laser printers require paper types and specifications that were uncommon just a decade ago.
Until then, no distinction was made between writing paper and xerographic paper. The
manufacture of paper is complex. Several different mills may offer the same type of paper (for
example, 25% cotton bond, writing stock) but each manufacturer will vary the texture, color,
fiber, lignin, coating, and other elements which make their product unique. In the paper
industry, there are no equivalent papers between manufacturers, only substitutes.

Sources of Paper
Paper is primarily made from cellulose fiber, the major component of the cell walls of wood
fibers and other plants. Sources of this fiber include:

• Raw Wood
• Recycled or waste wood
• Cotton
Pulping methods are based, in part, on the fiber length of the raw wood. Hardwoods, such as
cottonwood, contain short fibers, from one to two millimeters in length. Softwood fibers,
including pine, spruce, and other conifers range in length from three to six millimeters. In each
case, the thickness is less than that of a human hair.
These differences often mean variability among paper manufacturers, even within the same
company. To ensure quality and consistency, a certain percentage of this material must come
from raw wood. Timber may be harvested from national forests and private land as well as tree
farms or plantations.

Surface Coatings
A thin layer of coating may be applied to the paper which could change its physical
characteristics. These surface coatings or “sizings” are added to make the sheets more resistant
to ink or water penetration and to increase durability. Coatings may also be added to create a
neutral pH in paper used for archival storage (such as legal documents). Surface coatings are
usually liquid starches and are applied either by spraying, immersion, or mixing into the
furnish.
Heavy coatings of clay or talc should be avoided because they become hard and brittle, causing
the fibers to break like a piece of chalk and come off during printer operation. Surface coatings
also affect the surface electrical resistivity, which is a important factor in the performance of
your D640 printers.

D-2

Using Paper

Cast Surfaces
When a very smooth surface is required, a clay and water solution is applied to the paper, and
is then “cast” under high temperatures. Cast surface paper is mainly used for offset color
presses and making original typeset master sheets used in publication printing. This type of
paper is not recommended for D640 printers because clay is very abrasive to components in
the paper path.

Packaging
Packaging is an important step in the paper-making process. Much of the paper used for
computing printing applications is packaged in reams: wrapped bundles containing 500 sheets.
Because paper is hygroscopic, or capable of absorbing or losing moisture from the air, it
should be protected by moisture-proof polylaminated wrapping and moisture barriers. A ream
of finished paper usually contains about 4% moisture. The paper ream remains stable if
properly stored and opened only when ready to be used.

Paper Ream Label
A ream label is placed on the outside of the paper wrapping. The ream label usually indicates
paper: basis weight, size, number of sheets, grain direction and grade. The printing surface of
the paper may be indicated by an arrow on the ream label. Paper should be loaded into the
printer so that surface indicated by the arrow will be the printing surface. The printing surface
may be up or down, depending on the printer model and the paper feeding source.

Figure D-1

Ream Label

Media Selection Specifications and Guidelines
Hewlett-Packard neither warrants nor recommends the use of a particular print media. Media
properties are subject to change by manufacturers and Hewlett-Packard has no control over
such changes. The customer assumes all responsibility for the quality and performance of
media. Although testing media helps to characterize their performance, long-term satisfaction
requires process quality control by the manufacturer and proper handling until use.

Using Paper

D-3

Using Paper

Media Selection Specifications and Guidelines

Recommendations to the Customer
Hewlett-Packard D640 printers are designed to be as flexible as possible in the types of print
media they can use. Since there are many varieties of media and variations in the
manufacturing process, you should test a particular medium in your environment to determine
if it performs acceptably.

Buy Media that Meets Specifications
To get the best performance from your D640 printer, select high quality print media that meet
the guidelines and specifications in this document.

Test Small Amounts of Media
The next step in choosing media, particularly if you are planning a large purchase, is to print a
small quantity in your environment. Subject it to the temperature, humidity, and printing
application in which it will be operating. DO NOT purchase large quantities without first
testing the media! Hewlett-Packard recommends that you ask your media vendor for a
guarantee that their media will perform satisfactorily in your D640 printer, and that you ask the
vendor to assume responsibility for the replacement of any media that will not print
acceptably.

Use High Quality Media
Hewlett-Packard printers will work best with high quality media. Quality media for D640
printers are characterized by uniform physical properties, freedom from dust and lint, accurate
cutting to size, and packaging that protects it from moisture and physical damage. Curled or
bent edges, spots, dust or lint, wrinkling, and inaccurate cutting to size are common media
problems that should be avoided. These problems can cause misfeeding, jamming, premature
wear, or unsatisfactory print quality.

Size
Table D-1, “Paper sizes” shows paper sizes that can be used with D640 printers. Shown also is
the numeric code displayed on the operator panel for each paper size. All paper sizes can be
used in either simplex or duplex printing modes. Use only paper that is within the dimensions
shown in Table D-1, “Paper sizes”.
Note Although the D640 printer can print over the entire sheet, we do not guarantee quality
for print in the outer 5mm of the page periphery. This border will vary slightly with the quality
of the paper used.
Table D-1

Paper sizes

Size

Dimensions

11.69 X 16.53 in.

297 X 420 mm

8.26 X 11.69 in.

210 X 297 mm

D-4

Using Paper

Table D-1

Using Paper

Media Selection Specifications and Guidelines

Paper sizes

Size

Dimensions

5.84 X 8.26 in.

149 X 210 mm

JIS B4

10.11 X 14.32 in.

257 x 364 mm

JIS B5

7.16 X 10.11 in.

182 X 257 mm

Letter

8.5 X 11 in.

216 X 280 mm

Legal

8.5 X 14 in.

216 X 356 mm

Ledger

11 X 17 in.

280 X 432 mm

Executive

7.25 X 10.5 in.

184 X 267 mm

Basis Weight
Basis weight is an important characteristic to consider because, paper that is too light or too
heavy may cause misfeeds, mis-stacking, paper jams, or excessive mechanical wear.
The printer is specifically designed to perform at maximum efficiency when 20 pound bond
(75g/m2) paper is used. Optimum print quality and paper path reliability are achieved when
high quality electrophotographic (EP) paper is used. EP papers have specific characteristics
that distinguish them from bond papers. The range of paper weight that the printer and HCI can
process is 17 to 24 pound (64 to 90 g/m 2). The printer can handle paper weights up to 36
pound (135 g/m2), but 17 to 24 is optimum.
Specifications for basis weight depend upon the paper source the paper is fed. In general, the
straighter the paper path, the heavier the basis weight may be. For more complex paper paths,
as in feeding from the HCI, a lighter weight may be required, in range of 18 to 24 pound.

Furnish (Composition)
Furnish is the fiber and chemical composition of paper. Fiber composition of the paper used in
D640 printers should be manufactured from 100 percent chemical wood pulp and/or cotton
fiber. To ensure that paper of a special fiber composition will work properly, always test it
before purchasing large quantities. Other allowable components of paper are sizing, fillers,
buffers and pigments.
Note DO NOT use coated paper or paper containing materials that melt, vaporize, offset,
discolor or release hazardous emissions when exposed to 392°F (200°C).

Using Paper

D-5

Media Selection Specifications and Guidelines

Curl
Curl is curvature in a sheet of paper. Curl is typically measured by laying the sheet of paper on
a flat surface, with the corners up, and measuring the height of the corners. In-ream curl is the
amount of curl a sheet of paper has before printing. (In-ream curl may result from the paper
manufacturing process or from exposure to the environment). Post-image curl is the amount of
curl a sheet of paper has after printing (from exposure to the fusing process and paper path in
the printer). Paper with excessive in-ream curl may lead to feeding and print quality problems.
In addition paper with excessive post-image curl may be difficult to handle or use in
automatic-feed photocopiers.
The curl side of the paper can be identified by a slight concave bowing from the outside edges
of the paper stack towards the center of the top sheet. This curled side is always the side that
should face away from the printer’s photoconductor. Having the curl side face away from the
photoconductor helps the paper separate from the photoconductor surface during the printing
process.
Paper curl becomes more obvious after fusing of a print. If the curl of a printed page appears
too excessive, it is likely that paper handling problems may occur during duplex printing. If
this is the situation, open the paper tray and turn the paper over. Try printing again. If the
problem is still not resolved, select a different paper for duplex printing, and reserve the
“problem” paper for single-sided printing.
Besides paper handling problems, excessive curl may also result in blurred print and similar
print quality problems. The HP standard for in-ream paper curl is no more than 0.2 inches
(5 mm) on any part of the paper, with 0.1 inches (3 mm) the optimal value.

Finish (Texture)
Finish, or texture, is the degree to which the surface is free of irregularities (or the smoothness
or roughness of the paper). Using paper that meets HP specifications for surface texture is
critical to the operation of D640 printers. The degree of surface texture is determined by the
fiber composition of the paper, fillers which may have been added to the paper mixture, and
the number of passes through the calendar stacks. Common paper textures included
cockleshell, linen and laid.

D-6

Using Paper

Potential Problems
Some textures improve paper feeding while others hinder the feed operation. Too smooth or
too rough paper can cause a variety of problems in D640 printers.
Table D-2

Finish (texture) potential problems

Problems
Feeding

Print
Quality

Too Smooth

Too Rough

• misfeeds

• misfeeds
• multi-feeds

• poor toner adhesion
• washout will show up (loose

• poor toner adhesion
• light and dark transitions (toner

•

toner particles from a previously printed page)
background toner scatter

none

Premature
Wear

migrates to the valleys of the paper
surface, but not the peaks)
printed characters may have broken
edges

• registration roller
• paper path rollers
• fuser
• paper path guides

Felt Side vs.Wire Side
The way paper is manufactured results in two-sided paper properties. This, along with other
process variations, may make one side of the paper the preferred side to print on. The “top”
side of the paper sheet as it is formed is known as the felt side, and the “bottom” is known as
the wire side. Most manufacturers indicate the preferred printing side on the package.

Moisture Content
Note Moisture content is the most critical factor in paper performance in D640 printers. The
moisture content of most paper at the time of manufacture is about 4-6% of volume by weight.
This percentage can be altered as a result of environmental conditions during converting
processes, shipping, storage, and printing.
Storage, especially over long periods, can greatly influence moisture content. Because of the
hygroscopic properties of paper, unless proper humidity and temperature are maintained, the
paper will lose or gain moisture.

Using Paper

D-7

Using Paper

Media Selection Specifications and Guidelines

The environmental conditions required to maintain the proper moisture content is 68°F to
75°F (20°C to 24°C) with a relative humidity of 45% to 55%.
Table D-3
Too Moist

Moisture content potential problems

• Paper shrinks unevenly during fusing, causing print quality problems
• Overall paper curl increases (increases post-image curl, causes poor toner
adhesion, feed and print quality problems)

Too Dry

• Excess static (causes multi-feeds and paper jams)
• Surface electrical resistivity (causes streaking and smudging of loose toner
particles)

The HP standard for moisture content is 4.7% ± 1% by weight. Although a paper may have the
proper moisture content at the time of manufacture, exposure to temperature and humidity
extremes may alter the percentage.

Fusing Compatibility
Media that does not meet HP specifications may:

•
•
•
•
•
•
•
•

Discolor
Melt
Scorch
Offset
Release hazardous emissions
Have poor toner adhesion
Break down in other ways
Possibly damage the printer

All media used in D640 printers must have the ability to withstand the fusing temperature of
392°C/200°C for 0.1 second, without experiencing any problems.
Inspect the rollers for colored ink build-up from pre-printed logos or letterhead and for toner
buildup or spots. Inspect printed output for repetitive defects and smearing. If necessary,
contact your forms vendor to ensure paper’s fusing compatibility with D640 printers.

D-8

Using Paper

Understanding Paper Ream Labels
Figure D-2, shown below, is an example of a typical label from a ream of paper. It includes
much of the information about paper use and paper specifications.

Figure D-2

Paper Ream Label details

General Guidelines
Some general guidelines to follow when selecting media are summarized on the following
pages.
Use conventional white xerographic paper for most printing. The paper should be of high
quality, free of cuts, tears, grease spots, loose particles, dust, wrinkles, voids, and curled or
bent edges. Xerographic papers, also called photocopy or xerocopy papers, are usually made
from chemical wood pulp and are characterized by a smooth surface, controlled electrical
properties, heat stability, and cleanliness. These characteristics ensure good image transfer,
fusing without excessive curl, and reliable printer operation.
Some applications may require a paper having a more prestigious look or feel. Bond papers
generally have a watermark and often use cotton fiber. These papers tend to have a rougher
surface and their properties may not be controlled like xerographic papers. However, your
D640 printer will print satisfactorily on many of these bond papers. Also, some paper
manufacturers are now making laser grade bond papers which have properties compatible with
laser quality printing.
One of the most important things you can do to ensure the best possible performance from your
D640 printer is to select a quality paper. Table D-4, “Recommended paper specifications”,
summarizes the specifications of a paper that will give you the best performance.

Using Paper

D-9

Using Paper

Understanding Paper Ream Labels

General Guidelines

Note It is possible that paper could meet all of the general specifications listed in this table
and still not print satisfactorily because of the printing environment or other variables over
which Hewlett-Packard has no control.

Recommended Paper Specification Summary
Table D-4

Hp D640 Users Manual

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