Hp D640 Users Manual

2015-02-09

: Hp Hp-D640-Users-Manual-548694 hp-d640-users-manual-548694 hp pdf

Open the PDF directly: View PDF PDF.
Page Count: 293 [warning: Documents this large are best viewed by clicking the View PDF Link!]

User Manual
Model D640
(Printer and Accessories)
HP 5000
Cut Sheet
Printers
HP 5000
D640 Cut Sheet Printer
User Manual
(Printer and Accessories)
Hewlett-Packard Company
C5620-90024
E0397
ii
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 consequen-
tial 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 equip-
ment 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
iii
Copyrights and Trademark Credits
Adobe™, PostScript™, PostScript II and the PostScript Logo™ are trademarks of Adobe Sys-
tems Incorporated which may be registered in certain jurisdictions.
Arial, Times New Roman, and Monotype are registered trademarks of the Monotype Corpora-
tion.
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, Cou-
rier, Garamond, Letter Gothic, Marigold, Symbol, Times New Roman, Univers, Univers Con-
densed, Wingdings are trademarks of Agfa Division of Miles Inc.
CG Times, a product of Agfa Corporation, is based on Times New Roman, a registered trade-
mark 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 Associ-
ates, Inc.
Other product names mentioned in this manual may also be trademarks and are used here for
identification only.
iv
Caution and Warnings
A Caution denotes a hazard. It calls attention to a procedure which, if done incorrectly or inat-
tentively, 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! Warning messages call attention to situations that could result in personal
injury.
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.
v
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 dis-
able 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.
vi
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 opera-
tions 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 chap-
ters 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 con-
sumables, 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 set-
tings 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.
vii
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 per-
form 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
ix
1 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
Table of Contents
x
2 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
3 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
xi
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
4 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
xii
Fuser Kit - Replacing the Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Removing the Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Installing the Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Printer Pick Roller Kit - Replacing the Tray Pick Rollers . . . . . . . . . . . . . . . 4-33
At the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Removing the Printer Pick Rollers (Upper and Lower) . . . . . . . . . . . . . . 4-33
New Printer Pick Roller Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Installing the Printer Lower Pick Rollers . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Installing the Printer Upper Pick Rollers . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Installing the Covers and Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
HCI Pick Roller Kit - Replacing the HCI Pick Rollers . . . . . . . . . . . . . . . . . 4-42
At the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Removing the HCI Pick Rollers (Upper and Lower) . . . . . . . . . . . . . . . . 4-42
New HCI Pick Roller Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Installing the HCI Lower Pick Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
5 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
xiii
6 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
xiv
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
xv
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
xvi
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
For installation and general printer questions, call: . . . . . . . . . . . . . . . . . . F-1
For hardware problems, call: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6
HP Maintenance Agreements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6
HP5000 Model D640 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6
About Your Printer 1-1
About Your
Printer
1
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
Accessories For the D640 Printer
1-2 About Your 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.
Accessories For the D640 Printer
About Your Printer 1-3
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.
Accessories For the D640 Printer
1-4 About Your 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.
Getting to Know the Printer
About Your Printer 1-5
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.
Figure 1-2 D640 with High Capacity Input and High Capacity Output
LTR
LTR
LTR
HCO D640 HCI
Printer
Getting to Know the Printer
1-6 About Your 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.
Figure 1-3 Front and right side of the printer
.
.
.
.
.
.
.
.
.
..
.
.
.
.
...
Paper output tray
Ejection unit
Upper right cover
Lower right cover
Main power switch
Paper level indicators
Paper size indicators
Front cover
Front door
Tray1
Tray2
Tray3
..
.
.
....
.
.
.
.
......
Power Save Mode Indicator
Screen contrast control
Function buttons
LCD Panel
*Speaker
ON
* Not used
Standby switch
Control panel
Getting to Know the Printer
About Your Printer 1-7
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.
Getting to Know the Printer
1-8 About Your Printer
Figure 1-4 Behind the front cover
..
.
.
....
.
..
.
.
.....
Floppy disk drive
Front cover
Serial diagnostic port *
PC card slot *
LTR
LTR
LTR
* For support use only.
Getting to Know the Printer
About Your Printer 1-9
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.
Getting to Know the Printer
1-10 About Your Printer
Figure 1-5 Behind the front door
Transfer assembly guide
Lever 6
Handle 3
Fuser unit
Decurler lever
Lever 4
Duplex unit
Drum unit locking knob
Drum unit
Precharger cleaner
Lever b1
Knob 1
Knob 2
..
.
.
....
.
..
.
.
.
....
Cleaning roller
LTR
Fuser locking knob
Lever 5
Duplex roller knob
Decurler roller
knob
Getting to Know the Printer
About Your Printer 1-11
About Your
Printer
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 double-
sided 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.
Getting to Know the Printer
1-12 About Your Printer
Figure 1-6 Behind the upper right cover
Toner collector bottle
Toner hopper
Developer unit
Developer collector bottle
Upper right cover
..
..
....
.
..
.
.
.....
Install toner here
Install developer here
Getting to Know the Printer
About Your Printer 1-13
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.
Getting to Know the Printer
1-14 About Your Printer
Figure 1-7 Rear and left side of the printer
Upper left cover
Paper side exit
(under cover)
HCO connector
AC input
power connector
HCI connector
Ozone filter
User documentation
holder
Serial port (RS232/422)
Switches used for support only
Parallel port
(IEEE 1284C)
HCO attachment
points (under covers)
Ejection unit
Lower connector
not used
Getting to Know the Printer
About Your Printer 1-15
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.
Getting to Know the Printer
1-16 About Your 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.
Figure 1-8 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.)
HCI release handle
Paper table lowering button
HCI door
Door handle
Paper table
(inside door)
Printer
Getting to Know the Printer
About Your Printer 1-17
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.
Figure 1-9 High Capacity Output accessory
Main Power Switch
Input power cord connector
HCO Interface
control cable
ON
OFF
Powering On the Printer
1-18 About Your Printer
Powering On the Printer
1. Locate the main power switch and standby switch as shown in Figure 1-10.
Figure 1-10 Standby switch and Main power switch
2. Turn on the Main power switch by pressing in at the top of the switch.
3. Turn on the Standby switch, as shown in Figure 1-11, by holding the switch in the up
position momentarily.
Figure 1-11 Turning on the standby switch
4. 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.
ON
ON
OFF
Main power switch
Standby switch
.
.
.
.
..
.
.
.
..
.
.
.
....
..
..
....
.
.
.
.
.
.....
Standby switch
MODEL D640
5000
ON
Screen contrast control
Control Panel 2-1
Control Panel
2
Control Panel
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 Go to:
• Understand Control Panel functions page 2-2
• Check the printer’s status page 2-3
• Check the printer’s paper page 2-5
• Select Custom menu settings page 2-9
• Select Printer menu settings page 2-11
• Select Configurations menu settings page 2-14
• Select PCL menu settings page 2-19
• Select Comms menu settings page 2-21
• Select Maintenance menu settings page 2-24
• Select PapSize menu settings page 2-26
• Select Test menu settings page 2-28
Getting to Know the Control Panel
2-2 Control Panel
Getting to Know the Control Panel
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.
..
..
....
.
.
.
.
.
.....
PowerSave indicator
Screen contrast control
Function buttons
LCD panel
Standby switch
Speaker
(not used)
ON
Checking Printer Status
Control Panel 2-3
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.
Figure 2-2 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).
Ready - - free
JUN 18 05:32.23
PCL
Offline
Offline
Custom Menu Test PapSize
600dpi
LTR
LTR
LTR
Online
Message field
Printer is offline
Checking Printer Status
2-4 Control Panel
•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.
Figure 2-3 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.
Figure 2-4 Problem status report
Clear
Offline
Menu Test PapSize
LTR
LTR
LTR
Offline
Toner empty
Add New Toner
PCL
Clear
Offline
Menu Test PapSize
LTR
LTR
LTR
Ejection unit cover open
Close ejection unit cover
PCL
Custom
Online
Checking Paper
Control Panel 2-5
Control Panel
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.
Figure 2-5 shows the paper supply and path information.
Figure 2-5 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 Symbol Description
Letter
(LTR)
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
A4 indicates that the tray is set to contain A4 size paper. The empty
symbol indicates the tray has no paper.
Legal
(LGL)
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.
Custom
(CUS)
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.
Ready - - free
JUN 18 05:32.23
PCL
Offline
Offline
Custom Menu Test PapSize
600dpi
LTR LTR
LTR
LTR
Current paper path
Online
Function Buttons
2-6 Control Panel
Table 2-1 lists all available standard paper categories and their respective sizes.
Table 2-1 Standard paper sizes
Function Buttons
The following illustration shows the function buttons assigned to the Main Screen. Table 2-2
describes how each function button is used with the Main Screen.
Figure 2-6 Main Screen 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 A3 indicates that A3 size paper is the specified paper size, but the missing
symbol indicates that the tray is open.
Category Dimensions Category Dimensions
Letter 8.5 x 11 in (216 x 279 mm) A4 8.26 x 11.69 in (210 x 297 mm)
Legal 8.5 x 14 in (216 x 356 mm) A5 5.84 x 8.26 in (149 x 210 mm)
Ledger 11 x 17 in (280 x 432 mm) B4 (JIS) 10.11 x 14.32 in (257 x 364 mm)
Executive 7.25 x 10.5 in (184 x 267 mm) B5 (JIS) 7.16 x 10.11 in (182 x 257 mm)
A3 11.69 x 16.53 in (297 x 420 mm)
Ready - - free
JUN 18 05:32.23
PCL
Offline
Offline
Custom Menu Test PapSize Commands
for each
button
LTR LTR
LTR
LTR
Online
Function
buttons
600 dpi
Function Buttons
Control Panel 2-7
Control Panel
Table 2-2 Control Panel Main Screen Function Buttons
Navigating Through the Control Panel
Submenu Arrow Buttons
Figure 2-7 shows the appearance of the Control Panel when you are ready to make selections
from the Control Panel menus. When you want to expand the menu selections (that is, examine
and select settings from submenus providing more options), use the arrow buttons (M, N, P,
and O) and the Select button. Table 2-3 describes how to use each arrow button.
Figure 2-7 Arrow Buttons
Button Function
Online/
Offline
Online/Offline toggles the printer from Offline to Online.
When Online, the printer is ready to print.
When Offline, the printer does not accept print requests. The printer goes
Offline automatically when a paper jam or other detected problems occur.
Custom Custom settings store and recall saved configuration settings.
You can store up to three different custom configuration settings.
Menu Menu provides access to five submenus: Printing, Configuration, PCL, Comms, and
Maintenance.
Test Test prints various maintenance and user reports. Test also provides access to files
stored on a floppy diskette or on the internal hard disk.
PapSize PapSize (paper size) provides a configuration menu for setting the paper size for each
paper source.
Offline
Online
Offline
Online
Online
Menu
Online
Printing
Configuration
PCL
Comms
Maintenance
Function Buttons
2-8 Control Panel
Table 2-3 Control Panel Submenu Function Buttons
Figure 2-8 shows continuation arrows to indicate there are additional items on a submenu.
Press N display the additional items. Figure 2-9 shows the menu choices after you press N.
Figure 2-8 Continuation arrows
Figure 2-9 Up and down continuation arrows
MPress to scroll up the list of items on the submenu.
NPress to scroll down the list of items on the submenu.
PIf an additional submenu is available, press this arrow to open the
submenu.
OPress to close a submenu and return to the previous menu level.
Select Press to select the setting highlighted on the submenu.
Online
tray1size =
Online
LEGAL
LEDGER
EXECUTIVE
A4
A5
LETTER
Select
Contination arrows
Online
Printing.copies
Online Select
7
8
9
10
11
12
Additional selection above
Additional selections below
Custom Menu Settings
Control Panel 2-9
Control Panel
Once you have highlighted the submenu selection (Figure 2-8), press the Select function
button to activate your selection and return to the previous level. The Online function button
will change to Save. You can make further changes to the settings, or press Save to store your
new settings and return the printer to a Ready -- free state.
Note Changes to menu settings can only be made in the Ready -- free state. If you try to
make a change and see the message "menus locked", it means that the printer is processing a
print job and changes cannot be made
Changes to settings are not permanently saved unless you press the Save button after making
all configuration changes. When you press Save, your new settings are stored in the power-on
configuration. If you do not Save, the new settings are only active until you change them again,
cycle power, or print a job that contains a reset command.
Custom Menu Settings
The printer provides a means to maintain three different Control Panel custom configurations.
This allows you to pre-program configurations for later use. Configuration items available
under the Printing, Configuration, PCL, Comms, and some of the Maintenance submenus are
saved as part of the custom settings.
1. On the Main Screen, press Custom to display Figure 2-10:
Figure 2-10 Custom Menu
2. Use M or N to highlight your selection:
Restore Restore is used to recall the printer’s power-on configuration, factory default
configuration, or one of the three custom configurations.
Save Save is used to store a new configuration as the power-on configuration or one
of the three custom settings. All configurations are stored in the printer.
Online
Custom
Online
Restore
Save
Custom Menu Settings
2-10 Control Panel
3. Use M or N to highlight the Save or Restore (Figure 2-10).
4. Use P to obtain more settings options (Figure 2-11).
5. Use M or N to highlight the option you want.
6. Press Select.
Figure 2-11 Custom restore and save menu settings
PwrOnConfig This location stores settings used at power-on or from a job reset.
Note: Whenever you change a configuration value, the Online button changes to
Save. If you press Save, the values are changed in the PwrOnConfig location.
CUSTOM2 This location stores one of three custom configurations.
CUSTOM3 This location stores one of three custom configurations.
CUSTOM4 This location stores one of three custom configurations.
FACTORY This location holds the factory default configuration. Highlight FACTORY and press
Select to restore the printer configuration to the factory default.
Online
Restore
Online Select
PwrOnConfig
CUSTOM2
CUSTOM3
CUSTOM4
FACTORY
Printing Menu Settings
Control Panel 2-11
Control Panel
Printing Menu Settings
The Printing menu provides access to configuration choices that directly affect how your
documents are printed. Figure 2-12 shows some of these.
If your software specifies different values than those programmed in the Control Panel, the
printer uses the values supplied with the printing job.
Figure 2-12 Printing Menu
When you see pointers on the screen pointing up or down, that indicates there are additional
selections available by using M or N to access them.
In the table below, * indicates that a setting is present only if required option is installed (HCI,
HCO, PostScript). The equals sign (=) indicates the factory default value.
Copies =1 (minimum)
32767 (maximum) Sets the number of copies to be printed for each page.
Intray
=TRAY1
TRAY2
TRAY3
=HCI* (Default if HCI
is present
Sets the default media input source.
Paper
=auto
LETTER
LEGAL
LEDGER
EXECUTIVE
A4
A5
A3
JISB4
JISB5
CUSTOM
Sets the default image the page will be formatted for.
Auto uses the page size of the selected intray.
*Outbin =UPPER
HCO-FACEDOWN
HCO-FACEUP
Sets the media output destination.
Online
Menu
Online
Printing
Configuration
PCL
Comms
Maintenance
Printing Menu Settings
2-12 Control Panel
Duplex =OFF
ON Turns double-sided printing on or off.
Binding
=LONGEDGE
SHORTEDGE Sets the duplex binding options.
LONGEDGE (book) binding is the conventional side-to-side
binding used in books.
SHORTEDGE (tablet) binding is the traditional top to bottom
layout used with calendars.
Jobseparate
=none
TRAY1
TRAY2
TRAY3
Lets you dedicate an input tray to be used for job separation
sheets. "none" indicates that the job separation feature is not
enabled. Job separation sheets are usually colored paper.
When your print job contains a job separation command, the
printer will pick a sheet of paper from the designated tray and
insert it into the print job. No text is printed on the job
separation page. This feature can be used with the joboffset
feature if an HCO is connected.
*Joboffset =OFF
ON Enables the HCO offset (jogging) feature, which staggers
finished jobs for easy separation.
*HCI-Alias
TRAY1
TRAY2
TRAY3
=HCI
This setting redirects the HCI to act like tray1, tray2, tray3, or
like itself. It is provided primarily to make the D640 HCI act
just like an HP LaserJet IIIsi or 4si with an HCI, so jobs
configured for a LaserJet print correctly on the D640 without
modification.
To match a IIIsi or a 4si, change HCI-Alias to tray2. This will
cause all print job commands for tray2 (or lower tray) to pick
paper from the D640 HCI.
For more information, see “Configuring for LaserJet IIIsi and
4si Compatibility” on page 6-24.
Emulation
Allows you to select the printer emulation protocol. The selections are:
Auto - automatically selects PCL or PostScript* based on the print job data.
HEX - prints a "hexadecimal dump" of the print (used for troubleshooting).
PCL - is the standard PCL5e (4si) emulation protocol.
PS - is the optional PostScript* Level 2 emulation protocol.
Orientation
=PORTRAIT
LANDSCAPE
REVPORTRAIT
REVLANDSCAPE
Selects the print orientation. The figure below shows print
orientation.
Portrait
ABC
Landscape
ABC
Reverse
Portrait Reverse
Landscape
ABC
ABC
Printing Menu Settings
Control Panel 2-13
Control Panel
Lpi 0.01 (minimum)
= 6.00
100.00 (maximum)
Sets the number of lines per inch to print.
Error-Report
=none
ERRORS
WARNINGS
The printer is capable of printing errors found while
processing a job. This works for PCL or PS jobs and is
typically used to help troubleshoot a file which does not print
correctly. The options are:
none - turns error reporting off.
ERRORS - prints all fatal errors that prevent the job from
printing correctly.
WARNINGS - prints all fatal and nonfatal errors. Non-fatal
errors indicate minor processing problems. For example,
when the printer can’t process a command because of bad
syntax.
Configuration Menu Settings
2-14 Control Panel
Configuration Menu Settings
The Configuration menu (Figure 2-13) provides access to choices that affect general printer
operation. Figure 2-14 shows an example of Configuration menu selections.
Figure 2-13 Configuration Menu
Figure 2-14 Configuration Menu selections
When you see pointers on the screen pointing up or down, that indicates there are additional
selections available by using M or N to access them.
Online
Menu
Online
Printing
Configuration
PCL
Comms
Maintenance
Online
Configuration
Online
traylock
sizes
imageshift
customsize
units
newline =CR+LF
=Confirm
=1/720"
Configuration Menu Settings
Control Panel 2-15
Control Panel
In the table below, * indicates that a setting is present only if required option is installed (HCI,
HCO, PostScript). The equals sign (=) indicates the factory default value.
Newline
=CR + LF
CR
LF
CR or LF
Sets the method of newline interpretation. Some files may
contain carriage returns without line feeds, or line feeds
without carriage returns. Use this setting to print such files
properly.
Traylock.tray
1, 2, 3, and
HCI
tray1
=UNLOCKED
LOCKED
tray2
=UNLOCKED
LOCKED
tray3
=UNLOCKED
LOCKED
*hci
=UNLOCKED
LOCKED
Trays can be locked out of the automatic paper selection
process. Lock out paper trays if you don’t want the tray to be
available unless a job delivers a direct command to pick from
that tray. As an example, if you have a tray with letterhead in it,
you may want to lock out this tray so that if the other two trays
ran out of paper, the letterhead would not automatically be
used. Locked trays are only selected if the print job contains
the command to select the locked tray.
Sizes
= CONFIRM
CONTINUE
US
ISO
This setting specifies how the printer behaves when it receives
a request for a size of media not currently configured in the
printer.
CONFIRM - the printer stops and waits for the operator to
intervene. In this case, the following message appears on the
Control Panel.
PAPER-SIZE MISMATCH
LOAD XX PAPER
CONTINUE - the printer uses the next larger size of paper and
prints without any message.
US - the printer uses Letter paper in place of A4 paper, Ledger
paper in place of A3 paper, and Executive paper in place of A5
paper.
ISO - the printer uses A4 paper in place of Letter paper, A3
paper in place of Ledger paper, and A5 paper in place of
Executive paper.
Note The printer does not automatically resize the
print image for the new paper size. As a result, some
print data may not appear on the printed page.
Configuration Menu Settings
2-16 Control Panel
Imageshift.top
-720(min)
= 0
720(max)
This setting allows you to incrementally adjust the top position
of the image on paper in units, an incremental adjustment. The
factory default unit scale is 1/720", but you can reset the unit
size with the unit setting (see “Unit” on page 2-17). A typical
situation is alignment of text to a pre-printed form. You can
adjust within a range of 1 inch positive and 1 inch negative, in
1/720" increments, as listed below.
Imageshift.left
-720(min)
= 0
720(max)
This setting allows you to incrementally adjust the left position
of the image on paper in units, an incremental adjustment. The
factory default unit scale is 1/720", but you can reset the unit
size with the unit setting (see “Unit” on page 2-17). A typical
situation is alignment of text to a pre-printed form. You can
adjust within a range of 1 inch positive and 1 inch negative, in
1/720" increments, as listed below.
inch milli
meter
Unit Size Setting Range
1/100" 1/200" 1/300" 1/600" 1/720" mm
Minimum -1 -25.4 -100 -200 -300 -600 -720 -25
Maximum +1 +25.4 +100 +200 +300 +600 +720 +25
Customsize.width
2837(min)
=8417
8417(max)
This setting configures the media size of nonstandard media. It
is only used when you have a custom paper tray and one of the
PapSize values is set to Cus(custom). The table below lists the
minimum and maximum custom paper widths in units, an
incremental adjustment. The factory default unit scale is 1/720",
but you can reset the unit size with the unit setting (see “Unit” on
page 2-17).
customsize.width inch milli
meter
Unit Size Setting Range
1/100" 1/200" 1/300" 1/600" 1/720" mm
Minimum 4.72 120 394 788 1182 2364 2837 120
Maximum 11.69 297 1169 2338 3507 7014 8417 297
Configuration Menu Settings
Control Panel 2-17
Control Panel
Tip To make configuring the Imageshift and Customsize settings easier, set the units to
"MM" and make a coarse setting. Then, use a finer unit setting to fine tune the adjustment.
Customsize.height
5155 (min)
= 12240
12240(max)
This setting specifies the width dimensions of custom paper.
The table below lists the minimum and maximum custom paper
height in units, an incremental adjustment. The factory default
unit scale is 1/720", but you can reset the unit size with the unit
setting (see “Unit” on page 2-17).
customsize.height inch milli
meter
Unit Size Setting
1/100" 1/200" 1/300" 1/600" 1/720" MM
Minimum 7.17 182 716 1432 2148 4296 5155 182
Maximum 17.0 431.8 1700 3400 5100 10,200 12,240 432
Unit
1/100"
1/200"
1/300"
1/600"
1/720"
MM
Sets the unit values used in customsize and imageshift.
Dpi 200 dpi
300 dpi
=600 dpi
Sets the print resolution for graphic images in dots per inch (dpi).
Clip
OFF
=ON The D640 is able to print an image across the entire surface of the
physical paper. The image is clipped to prevent an image from
printing within 1/6th inch of any paper edge. This ensures optimum
print quality for the printed image.
If you don’t want this automatic clipping, you can set the printer to
Clip = OFF.
Even with Clip = OFF, the image will only print to the edge of the
paper if your print job contains the appropriate commands. See
“Setting Up Edge-to-Edge Printing” on page 6-23 for more
information.
Jamrecovery
=ON
OFF When a paper jam occurs, the printer reprints all pages that did not
completely exit the printer’s paper path. If you do not want pages to
automatically reprint after a paper jam is cleared, set Jamrecovery =
OFF.
Economode
=OFF
ON This setting specifies economy mode. When it is used for printing
drafts, you can save up to 30 percent of your toner consumption. In
economy mode solid black areas are filled in with a hatched pattern.
When economode is ON, the economode mark (e) appears in the
Control Panel, as shown in Figure 2-15.
Configuration Menu Settings
2-18 Control Panel
Figure 2-15 Economode
Powersave
off
15 MIN
30 MIN
=1 HR
2 HRS
3 HRS
This setting specifies the amount of time after the last print job
before the printer enters PowerSave. When the printer enters
PowerSave, it switches off the Control Panel backlight and lights
the green PowerSave indicator. Any activity on the printer serial or
parallel interface or Control Panel buttons restores full power.
Language
=ENGLISH
FRANCAIS
DEUTSCH
ESPANOL
ITALIANO
This setting specifies the language of text displayed on the Control
Panel and in reports under the test menu.
Ready - - free
JUN 18 05:32.23
PCL
Offline
Offline
Custom Menu Test PapSize
600dpi
LTR
LTR
LTR
Online
e
Economode
PCL Menu Settings
Control Panel 2-19
Control Panel
PCL Menu Settings
The PCL menu (Figure 2-16) lets you set the printer’s default font and symbol set. You can
also use the PCL menu to configure up to two active font cartridges. The selections are shown
in Figure 2-17.
When you see pointers on the screen pointing up or down, that indicates there are additional
selections available by using M or N to access them.
Figure 2-16 PCL Menu
Figure 2-17 PCL Menu selections
Online
Menu
Online
Printing
Configuration
PCL
Comms
Maintenance
Online
PCL
Online
=Courier
symbolset =ROMAN8 8U
pitch =10.00
pointsize =12.00
vcartridge1 =none
vcartridge2 =none
font
PCL Menu Settings
2-20 Control Panel
Font Sets the default character font.
Symbolset Sets the default symbol set (character set) of the font specified in the font setting. A
symbol set is a collection of letters, numbers, and symbols designed for specific
applications such as scientific equations and international language.
Pitch
Sets the default pitch size for the fixed-pitched font. Pitch is the number of characters that
can be printed in one horizontal inch. For example, a font with a pitch of 10 will print 10
characters for every horizontal inch of text. If a proportionally-spaced font is selected in
the font menu, pitch will not appear on the PCL menu.
Pointsize This setting specifies the point size for the scalable font. Pointsize is the height of the font
measured in point (1/72 of an inch).
Virtual
Font
Cartridges
The D640 printer is designed to be compatible with the HP LaserJet 4si. The 4si has two
slots available for font cartridges. HP sells over 50 different font cartridges for 4si and
compatible printers.
The D640 has no slots to hold these cartridges. Instead, we provide the same
functionality with virtual font cartridges. All of the font sets from all of the LaserJet 4si font
cartridges sold by Hewlett-Packard are stored on the D640’s internal hard disk drive. You
select the virtual font cartridge by vcartridge1 and vcartridge2. The font names are
comparable to the actual physical cartridge. For a complete list of the fonts available,
refer to “Using Virtual Font Cartridges” on page 6-26.
Note: Fonts located inside a font cartridge cannot be the printer default font.
Vcartridge1
= None
.
.
.
Printer16
Sets the font cartridge used in virtual font cartridge 1. A cartridge is
a set of fonts. Specified fonts appear at the bottom of the items in
the Font menu. Using vcartridge1 and vcartridge2 together, you
can choose two font sets.
Vcartridge2
= None
.
.
.
Printer16
Sets the font cartridge used in virtual font cartridge 2.
Comms Menu Settings
Control Panel 2-21
Control Panel
Comms Menu Settings
The Comms menu (Figure 2-18) contains options for configuring the printer’s parallel and
serial interface ports. The selections are shown in Figure 2-19.
When you see pointers on the screen pointing up or down, that indicates there are additional
selections available by using M or N to access them.
Figure 2-18 Comms Menu
Figure 2-19 Comms Menu selections
Online
Menu
Online
Printing
Configuration
PCL
Comms
Maintenance
Online
Comms
Online
timeout =15
databuffer =32
parallel
serial
Comms Menu Settings
2-22 Control Panel
Figure 2-20 Incoming data processing bar
Timeout none
=15
300 (max)
Sets the time limit (in seconds) that the printer waits before ending an
incomplete job or switching data ports (serial or parallel). When set to
none, the printer waits for you to manually intervene.
Databuffer
1 (min)
=32
1000(max)
(in Kb)
Sets the size of printer memory allocated for incoming data. Increasing
the data buffer size helps the host transfer data more quickly, but the
printer has less memory to store pages for printing. Decreasing the data
buffer size limits how quickly the host transfers data, but the printer has
more memory for processing and storing pages.The amount of data in
the buffer, relative to its overall size, is displayed as an expanding and
contracting horizontal bar (Figure 2-20) during the processing cycle.
Parallel
This setting specifies Busy signal timing for the Centronics parallel interface.
speed = SLOW Slow setting provides compatibility with older parallel
interfaces on personal computers and should only be
selected if you see characters missing in your printout.
speed = FAST Fast setting provides optimal performance and is the
preferred setting.
mode = COMPATIBLE This setting operates only in uni-directional mode for
downwards compatibility.
mode = ADVANCED This setting enables the use of IEEE-1284 bi-directional
communication (nibble-mode).
Serial
=baud
stopbits
parity
flow
dtr
levels
This setting specifies the serial interface communication options. See below
for an example of how these options are used together.
Printer initializing
Please Wait
PCL
Offline
Offline
Custom Menu Test PapSize
600dpi
LTR
LTR
LTR
Online
Cen
Comms Menu Settings
Control Panel 2-23
Control Panel
Serial Interface Configuration Example
The following is an example of how to configure the serial interface.
1. On Comms menu, use N to highlight Serial. At Serial, use P to display selections.
2. Use P to display baud rates.
3. Use N to scroll to display selections (19200 selected).
4. Continue selecting the following parameters:
• Select stopbits and set the number of stopbits.
• Select parity and set the parity check condition.
• Select flow and set the flow control type of the serial interface:
NOFLOW Disable flow control.
XON/XOFF Enable XON/XOFF flow control.
ROBUST Enable ROBUST flow control (a combination of software and hardware
flow control).
• Select dtr and set the method of handling the serial interface Data Terminal Ready
(DTR) signal.
HI/LO DTR polarity high for ready and low for not ready
LO/HI DTR polarity low for ready and high for not ready
HI/HI DTR polarity permanently high
LO/LO DTR polarity permanently low
• Select levels and set the type of serial interface.
Maintenance Menu Settings
2-24 Control Panel
Maintenance Menu Settings
The Maintenance Menu (Figure 2-21) contains options that help you maintain the D640 for
optimum print quality. The selections are shown in Figure 2-22.
When you see pointers on the screen pointing up or down, that indicates there are additional
selections available by using M or N to access them.
Figure 2-21 Maintenance Menu
Figure 2-22 Maintenance selections
Online
Menu
Online
Printing
Configuration
PCL
Comms
Maintenance
Online
Maintenance
Online
replace
alignment
density = 10
testpages = 30
monitor = OFF
date-time
Maintenance Menu Settings
Control Panel 2-25
Control Panel
Replace
The Replace selection initiates the replacement procedure
for the consumable items you are removing and replacing.
Follow the instructions in “Overview of Consumable
Supplies” on page 4-1 for replacing consumables.
Alignment.tray1,
tray2, tray3, hci,
duplex, and
duplexv
Sets the alignment correction values. See “Using Virtual Font Cartridges” on
page 6-26 for the paper path alignment procedure.
Density
1 (min)
= 10
15 (max)
This setting specifies the relative darkness of the print on a
scale of 1 to 15, with 15 being the darkest setting. Gray scale
patterns show the most visible effect. The effect of changing
Density can be seen immediately.
Note: The higher the density number, the quicker toner is
used. To conserve toner, use a lower setting.
Testpages
cont1 (min)
=30
30000 (max)
Sets the number of pages printed when you print the
testpage in the Test menu. The cont selection causes printing
to continue until you press End and select ABANDON.
Monitor = OFF
ON Turns on a special area on the Control Panel which displays
printer registers. This should only be set to ON when directed
by your service provider for troubleshooting.
Date-Time
minute =0-59
hour = 0-23
date = 1-31
month = JAN-DEC
year = (last 2 digits
of year)
Sets the current date and time. The date and time is
displayed on the Control Panel and printed on all test reports.
PapSize Menu Settings
2-26 Control Panel
PapSize Menu Settings
PapSize provides access to configure the paper size in the input trays and the HCI.
When you see pointers on the screen pointing up or down, that indicates there are additional
selections available by using M or N to access them.
In the table below, * indicates that a setting is present only if required option is installed (HCI,
HCO, PostScript). The equals sign (=) indicates the factory default value.
Figure 2-23 PapSize Button
Figure 2-24 PapSize selections
Ready - - free
JUN 18 05:32.23
PCL
Offline
Offline
Custom Menu Test PapSize
600dpi
LTR
LTR
LTR
Online
Message field
Printer is offline
Online
PapSize
Online
tray1size =LETTER
tray2size =LETTER
tray3size =LETTER
PapSize Menu Settings
Control Panel 2-27
Control Panel
Note The printer does not automatically sense the size of the paper installed in the trays.
You must set the size into the menu settings. If you change the size of the paper, change the
associated menu setting.
Tray1size
Tray2size
Tray3size
*HCIsize
=LETTER
LEGAL
LEDGER
EXECUTIVE
A4
A5
A3
JISB4
JISB5
CUSTOM
Sets the paper size for tray1, tray2, tray3 and the HCI (if installed).
The HCIsize setting only indicates letter or A4 as these are the only
sizes supported by the HCI.
Test Menu Settings
2-28 Control Panel
Test Menu Settings
The Test menu provides access to various print reports and file operations. Use the Test
functions to print out Setup, Maintenance, and Configuration reports, and also to access files
on the D640’s floppy drive and internal hard disk.
The Test functions are shown in Figure 2-25 and Figure 2-26.
“Printing Reports” on page E-1 provides the procedure for printing out the Setups,
Maintenance, Fonts, Table, Menus, and Testprint reports.
Figure 2-25 Test Function Button
Figure 2-26 Test selections
Ready - - free
JUN 18 05:32.23
PCL
Offline
Offline
Custom Menu Test PapSize
600dpi
LTR
LTR
LTR
Online
Message field
Printer is offline
Online
Test
Online Select
MAINT
FONTS
TABLE
MENUS
TESTPRINT
SETUPS
Test Menu Settings
Control Panel 2-29
Control Panel
Report Name Report Contents
SETUPS
Report
• Printing Menu lists the current print job requirements.
• Configuration Menu lists the printer’s image processing requirements.
• PCL Menu lists font characteristics.
• Comms Menu lists printer interface communication requirements.
• Maintenance Menu lists printer alignment characteristics that affect images.
• PapSize Menu lists current paper sizes in each tray.
• Printer Information lists the printer’s buffer information for maintenance purposes.
• Drive A floppy diskette; (3.5 inch floppy drive) shows floppy status (installed/not
installed).
• Drive C (hard drive) lists the hard drive characteristics.
MAINT
• Engine Status lists maintenance information.
• Maintenance Counters list the consumables usage by based on drum revolutions
and duty cycle. The numbers are based on life expectancy of these consumables.
You are responsible for maintenance of these consumables on a schedule
presented in “Maintenance” on page 5-1.
• Event Log lists all printer-captured events (such as paper jams and errors) and
the time and date consumables are replaced.
FONTS Typeface Report lists all available typefaces currently installed in the D640’s virtual
cartridges.
TABLE Table provides images and programming codes for each available typeface.
MENUS Menus provides all current menu settings.
TESTPRINT Testprint provides a ripple test pattern.
filesA filesA is the printer’s 3.5 inch floppy disk drive (FDD) A-drive for inputting information.
filesC filesC is the printer’s C-drive (hard disk drive or HDD) list of directories and files.
Printer Tasks 3-1
Printer Tasks
3
Printer Tasks
Introduction
This chapter guides you through common tasks associated with frequent use of the printer.
If you want to: Go to:
• Remove and install the paper trays page 3-2
• Adjust the standard tray paper guides page 3-3
• Set standard paper sizes in the menu settings page 3-7
• Adjust the custom tray paper guides page 3-8
• Set custom paper sizes in the menu settings page 3-10
• Lock out a paper tray page 3-18
• Stop or interrupt a printing job page 3-21
• Diagnose and fix paper jams page 3-22
• Check error messages and troubleshooting page 3-49
Removing and Installing the Paper Trays
3-2 Printer Tasks
Removing and Installing the Paper Trays
1. Pull out the standard tray as shown in Figure 3-1.
Figure 3-1 Pulling out Standard Tray
2. Install the standard tray by sliding it back in.
3. Pull out the custom tray as shown in Figure 3-3. Angle the tray up slightly until it
disengages the tray guides on either side of the printer, then remove the tray as if it were
a standard tray.
Figure 3-2 Pulling out Custom Tray
Tray
LTR
LTR
LTR
Adjusting Standard Tray Paper Guides
Printer Tasks 3-3
Printer Tasks
4. Install the custom tray as shown in Figure 3-3. Angle the tray down slightly until it
engages the tray guides on either side of the printer, then push the tray in as if it were a
standard tray.
Figure 3-3 Installing Custom Tray
Adjusting Standard Tray Paper Guides
The printer’s standard tray accepts all the standard paper formats listed in and illustrated in
Figure 3-4. A set of moveable paper positioning guides lock into place in the paper trays, with
the paper size visible through a cutout on the guide.
Table 3-1 Paper size settings in Standard Tray
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)
A3 11.69 x 16.53 in (297 x 420 mm)
A4 8.26 x 11.69 in (210 x 297 mm)
A5 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
LTR
LTR
Adjusting Standard Tray Paper Guides
3-4 Printer Tasks
Figure 3-4 Paper Sizes quick reference
5.84 7.25 8.5 11
11.6910.118.267.16
8.26
10.11
10.5
11
11.7
14
14.32
16.53
17
(149 x 210mm)
(182 x 257mm)
(184 x 267mm) — 7.25 x 10.5 in.
(216 x 280mm) — 8.5 x 11 in.
(210 x 297mm)
(216 x 356mm) — 8.5 x 14 in.
(257 x 364mm)
(297 x 420mm)
280 x 432mm) — 11 x 17 in.
A5
JISB5
Executive
A4
Legal JISB4
A3
Ledger ("B" size)
Letter
Adjusting Standard Tray Paper Guides
Printer Tasks 3-5
Printer Tasks
1. Each paper guide has a blue locking thumbwheel, as shown in Figure 3-5.
Figure 3-5 Paper guides
2. Turn the blue locking thumbwheels on each paper guide counterclockwise to the OPEN
position (Figure 3-6).
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.
Guides
(3) Locking devices
LTR
LTR
LGR
C
L
O
S
E
O
P
E
N
LTR
Adjusting Standard Tray Paper Guides
3-6 Printer Tasks
Figure 3-7 Paper guide size selection
3. Adjust both paper guides for the same paper size.
4. Turn the blue locking thumbwheels on each paper guide clockwise to the CLOSE
position to secure it. (Figure 3-8).
Figure 3-8 Securing the paper guide
O
P
E
N
B4
LGL
B5
LTR
LGR
C
L
O
S
E
LTR
LTR
LGR
C
L
O
S
E
O
P
E
N
LTR
Setting Standard Paper Sizes
Printer Tasks 3-7
Printer Tasks
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.
Figure 3-9 PapSize
2. Verify that all trays have the correct paper size loaded.
3. Select the drawer using N. The selection is highlighted (for example, tray1size).
4. Press P and a list of sizes appears on the Control Panel (Figure 3-10).
Figure 3-10 Paper Size Selection
Online
PapSize
Online
tray1size =LETTER
tray2size =LETTER
tray3size =LETTER
Online
tray1size =
Online
LEGAL
LEDGER
EXECUTIVE
A4
A5
LETTER
Select
Contination arrows
Adjusting Custom Tray Paper Guides
3-8 Printer Tasks
5. Use M or N to move to the correct paper size (Figure 3-11).
Figure 3-11 Paper size selection continuation
6. 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.
tray1size
Online Select
JISB4
JISB5
CUSTOM
A3
Adjusting Custom Tray Paper Guides
Printer Tasks 3-9
Printer Tasks
1. Adjust the guides to the size of your paper. Figure 3-12 shows the adjustment guide
travel directions.
Figure 3-12 Custom Paper Tray guide adjustments
2. Load the paper in the tray as described in “Loading Paper Into Trays and HCI” on
page 3-16.
3. 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.
Squeeze lever to release
front and rear guides
Thumbscrews to adjust
left guide (finger tighten)
Setting Custom Paper Sizes
3-10 Printer Tasks
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.
Figure 3-13 Main Screen
2. Press M or N to highlight the tray to define as a CUSTOM tray.
Figure 3-14 Paper tray selections
Ready - - free
JUN 18 05:32.23
PCL
Offline
Offline
Custom Menu Test PapSize
600dpi
LTR
LTR
LTR
Online
Message field
Printer is offline
Online
PapSize
Online
tray1size =LETTER
tray2size =LETTER
tray3size =LETTER
Configuring Custom Tray Menu Settings
Printer Tasks 3-11
Printer Tasks
3. Press P to get a list of paper sizes for this tray, as shown in Figure 3-15.
Figure 3-15 Paper size selections
4. Press N to move to CUSTOM.
5. Press Select to define this CUSTOM paper size selection (Figure 3-16).
Figure 3-16 Paper size (continuation of selections)
6. 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. 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.
2. The 8 inch side is height. You could also select the short side as the height.
Online
tray1size =
Online
LEGAL
LEDGER
EXECUTIVE
A4
A5
LETTER
Select
Contination arrows
Online
tray1size
Online
JISB4
JISB5
Select
A3
CUSTOM
Configuring Custom Tray Menu Settings
3-12 Printer Tasks
3. 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.
4. 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 multipli-
cation is necessary.
5. Multiply your paper width by the number of units per inch (in our example,
100x5=500).
6. Press Menu on the Main Screen to display the Menu options, shown in Figure 3-17.
Figure 3-17 Menu options
7. Press N to highlight Configuration.
8. Press P to get Configuration options (Figure 3-18).
9. Press N to select units. (Figure 3-18).
Figure 3-18 Configuration options
Online
Menu
Online
Printing
Configuration
PCL
Comms
Maintenance
Online
Configuration
Online
newline
traylock
sizes
imageshift
customsize
units
= CR+LF
= CONFIRM
= 1/720"
Configuring Custom Tray Menu Settings
Printer Tasks 3-13
Printer Tasks
10. Press M or N to select your unit size selections (Figure 3-19).
Figure 3-19 Unit size selections
11. In our example, 1/100" is highlighted (Figure 3-20).
Figure 3-20 Highlighting 1/100"
12. Press Select. Figure 3-20 is displayed.
13. Press M to highlight customsize (Figure 3-21).
Figure 3-21 Customsize selection
Online
Configuration.units
Online Select
1/100"
1/200"
1/300"
1/600"
1/720"
MM
=
Online
Configuration.units
Online Select
1/100"
1/200"
1/300"
1/600"
1/720"
MM
Online
Configuration
Online
newline = CR+LF
traylock
sizes = CONFIRM
imageshift
customsize
units = 1/100"
Configuring Custom Tray Menu Settings
3-14 Printer Tasks
14. Press P to highlight width.
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).
Figure 3-23 Width selection for custom paper size
16. Press Select.
17. Press N to highlight height.
Online
Configuration.customsize
Online
width = 8416
height = 12240
Online
Configuration.customsize
Online Select
width = 500
501
502
503
504
505
Configuring Custom Tray Menu Settings
Printer Tasks 3-15
Printer Tasks
18. Press M or N until your number is highlighted (our example is 800, as shown in
Figure 3-24).
Figure 3-24 Height selection for Custom Paper Tray
19. Press Select.
20. Press Save.
Online
Configuration.customsize
Save Select
height = 800
801
802
803
804
805
Loading Paper Into Trays and HCI
3-16 Printer Tasks
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
1. 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.
Figure 3-25 Removing paper from the package
2. Inspect the paper for indented or interlocked edges, bent corners, wrinkled sheets, and
excess glue from the wrapper. Discard any damaged sheets.
3. Load the paper into the printer tray or HCI as recommended in the paper loading
illustrations provided in Table 3-2.
PRINT THIS SIDE FIRST
Loading Paper Into Trays and HCI
Printer Tasks 3-17
Printer Tasks
Table 3-2 Paper orientation in trays and HCI
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.
Input Tray HCI
Short edge leading Long edge leading
Single-sided
printing to
output tray
or
Double-sided
printing to HCO
Double-sided
printing to
output tray
TOF = Top Of
Form
TO
F
Face down
TOF
Face down
TOF
Face up
Face up
TOF
Face up
TOF
Face down
TOF
Locking Paper Trays
3-18 Printer Tasks
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. On the Main Screen, press Menu.
2. Press N to move to Configuration (Figure 3-26).
Figure 3-26 Configuration Menu
3. Press P to select Configuration.
Online
Menu
Online
Printing
Configuration
PCL
Comms
Maintenance
Locking Paper Trays
Printer Tasks 3-19
Printer Tasks
4. Press N to move to traylock (Figure 3-26).
Figure 3-27 traylock
5. Press P to select traylock.
6. Press M or N to move to the tray to lock (Figure 3-28).
Figure 3-28 Configuration.traylock
Online
Configuration =
Online
sizes = CONFIRM
imageshift
customsize
units = 1/720"
newline = CR + LF
traylock
Online
Configuration.traylock
Online
tray1 =UNLOCKED
tray2 =UNLOCKED
tray3 =UNLOCKED
Locking Paper Trays
3-20 Printer Tasks
7. For example, if you want to lock tray1, press P to select tray1. (See the screen in
Figure 3-29.)
Figure 3-29 Configuration.traylock.tray1
8. Press N to move to locked.
9. Press Select. You return to the Configuration.traylock screen with tray1 locked
(Figure 3-30).
Figure 3-30 Tray 1 locked
10. Press Save to save the changes in PwrOnConfig.
Online
Configuration.traylock.tray1 =
Online
LOCKED
tray1 = UNLOCKED
Select
Online
Configuration.traylock
Save
tray1= LOCKED
tray2 = UNLOCKED
tray3 = UNLOCKED
Stopping or Interrupting Print Jobs
Printer Tasks 3-21
Printer Tasks
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.
Figure 3-31 End Button
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.
Figure 3-32 End Submenu
Ready - - printing
JUN 18 05:32.23
PCL
Offline
Offline
Menu End
600dpi
LTR
LTR
LTR
Cen
Online
Online
End =
Online
ENDDOC
SUPPRESS
ABANDON
PAUSE
Select
Clearing a Paper Jam
3-22 Printer Tasks
The choices available are:
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.
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
Printer Tasks 3-23
Printer Tasks
Table 3-3 Paper jams and remedies
Paper Jam Messages Remedy Refer to
page
Paper Input Jams
TRAY1 Pick error
TRAY2 Pick error
TRAY3 Pick error
Remove tray (1, 2, or 3), remove paper jam from paper entry
area and/or within tray. 3-24
Feed jam 1 Open the front door, lower transfer assembly, rotate knob 1
counterclockwise and knob 2 clockwise to free paper,
remove jammed paper.
3-26
Feed jam 2 Open the side door, remove jammed paper. 3-26
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
counterclockwise and knob 2 clockwise to free paper,
remove jammed paper.
3-26
Paper Path Jams
Fuser unit jam 1
Fuser unit jam 2 Open the front door, lower transfer assembly, open lever 4,
push decurler lever down, remove jammed paper to the
right.
3-36
Duplex path jam 1
Duplex path jam 2 Open the front door, raise lever 6, and remove jammed
paper. You may need to turn duplex roller knob to release
the paper.
3-38
Print unit path jam (Reversing unit area jam)
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.
3-40
Paper Output Jams
Ejection unit jam 1
Ejection unit jam 2 Raise the paper ejection cover and remove jammed paper. 3-43
HCO jam 1
HCO jam 2 Open the HCO door, rotate roller knob 1 to free paper, then
lift levers to remove paper. 3-45
Clearing Paper Input Jams
3-24 Printer Tasks
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.
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.
Figure 3-34 Opening paper tray
Clear
Offline
Menu End
600dpi
LTR
LTR
LTR
Offline
Blinking
****
**** Pick error
Remove paper & Press Clear
PCL
TRAY1
TRAY2
TRAY3
LTR
LTR
LTR
Clearing Paper Input Jams
Printer Tasks 3-25
Printer Tasks
2. 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.
3. If you do not find any jammed paper, open the lower right cover and check for paper.
Figure 3-35 Removing paper jam from tray area
4. 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.
LTR
LTR LTR
Lower right cover
Clearing Paper Input Jams
3-26 Printer Tasks
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.
Figure 3-36 Feed path paper jam indication
1. 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).
2. 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.
Clear Menu Test PapSize
LTR
LTR
LTR
PCL Blinking
Feed path jam 1
Feed path jam 2
Feed path
j
am 4
*****:
Offline
Remove paper & Press Clear
.............
Clearing Paper Input Jams
Printer Tasks 3-27
Printer Tasks
Figure 3-37 Removing paper from side door opening
Figure 3-38 Unlatching the HCI
Lower right door
Paper
LTR
LTR
LTR
LTR
LTR
LTR
Clearing Paper Input Jams
3-28 Printer Tasks
3. If there is no paper there, close the door and if applicable, push the HCI inward to relatch
it.
4. 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.
5. 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.
Figure 3-39 Lowering Transfer Assembly
Handle 3
Clearing Paper Input Jams
Printer Tasks 3-29
Printer Tasks
6. 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. If the paper is not visible, reach into the area indicated in Figure 3-40 and feel for it.
8. Turn knob 1 counterclockwise and knob 2 clockwise to move paper into position for
removal, as shown in Figure 3-41.
Clearing Paper Input Jams
3-30 Printer Tasks
Figure 3-41 Turning Knobs 1 and 2
9. 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.
Knob 2 Knob 1
Clearing Paper Input Jams
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.
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.
Clearing Paper Input Jams
3-32 Printer Tasks
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.
Figure 3-43 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.
Figure 3-44 Opening the HCI door
Offline
Offline
Menu End
600dpi
LTR LTR
LTR
LTR
Offline
Blinking
HCI jam 2
Remove paper & Press Clear
PCL
Cen
LTR
LTR
LTR
Clearing Paper Input Jams
Printer Tasks 3-33
Printer Tasks
2. 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.
Figure 3-45 Removing paper from HCI
3. Close the HCI door as shown in Figure 3-46. The paper rises up to the operating
position automatically.
Figure 3-46 Closing the HCI door
4. 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.
LTR
LTR
LTR
LTR
LTR
LTR
Clearing Paper Input Jams
3-34 Printer Tasks
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.
Figure 3-47 Releasing the HCI from the printer
5. If there is paper hanging out of the printer or the HCI, remove it, as shown in
Figure 3-48:
Figure 3-48 Removing paper between the HCI and the printer
LTR
LTR
LTR
LTR
LTR
LTR
Clearing Paper Path Jams
Printer Tasks 3-35
Printer Tasks
6. Push the HCI towards the printer until it latches and check the Control Panel.
7. 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.
Figure 3-49 Paper path jams indication
Clear
Offline
Menu Test PapSize
LTR
LTR
LTR
*Offline*
Blinking
Fuser unit jam
Duplex path jam
Print unit path jam
*****:
PCL
Remove paper & Press Clear 600 dpi
Clearing Paper Path Jams
3-36 Printer Tasks
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.
Figure 3-50 Lowering Transfer Assembly
2. Turn Lever 4 fully clockwise (straight down) until stopped to relieve tension on the
paper, as shown in Figure 3-50.
3. 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.
Lever 4
Clearing Paper Path Jams
Printer Tasks 3-37
Printer Tasks
Figure 3-51 Removing Fuser Unit paper jam using Decurler Lever
4. 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
5. 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.
Thumb on
decurler lever
Clearing Paper Path Jams
3-38 Printer Tasks
Clearing a Duplex Unit Jam
The duplex unit jam is indicated on the Control Panel as shown in Figure 3-53.
Figure 3-53 Duplex Unit Paper Jam
1. Open the door and locate lever 6 as shown in Figure 3-54.
2. Lift lever 6 and turn the duplex roller knob to move any paper into view.
Figure 3-54 Freeing Duplex Jam
Clear
Offline
Menu End
600dpi
LTR
LTR
LTR
Blinking
PCL
Duplex path jam 2
Remove paper & Press Clear
Offline
Duplex roller knob
Lever 6
Clearing Paper Path Jams
Printer Tasks 3-39
Printer Tasks
3. Remove paper as shown in Figure 3-55 and close the door.
Figure 3-55 Removing paper jam from duplex path
4. 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.
Clearing Paper Path Jams
3-40 Printer Tasks
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.
Figure 3-56 Opening Lever 4
2. Locate Lever 5 and push it downward and away from the fuser unit area, as shown in
Figure 3-57.
Lever 4
Clearing Paper Path Jams
Printer Tasks 3-41
Printer Tasks
Figure 3-57 Freeing paper in Reversing Unit jam
3. If paper is not visible, turn decurler roller knob counterclockwise to move any paper into
view, or reach up into this area carefully.
4. Remove jammed paper, as shown in Figure 3-58.
Figure 3-58 Removing paper jam from reversing area
Lever 5
Decurler roller knob
Clearing Paper Path Jams
3-42 Printer Tasks
5. 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
6. 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.
Clearing Paper Output Jams
Printer Tasks 3-43
Printer Tasks
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.
Figure 3-60 Ejection Unit jam
1. Swing open the ejection unit cover as shown in Figure 3-61.
Figure 3-61 Opening the Ejection Cover
Clear
Offline
Menu End
600dpi
LTR
LTR
LTR
Offline
Blinking
Ejection unit jam 2
Remove paper & Press Clear
PCL
Clearing Paper Output Jams
3-44 Printer Tasks
2. 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. 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.
Clearing Paper Output Jams
Printer Tasks 3-45
Printer Tasks
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.
Figure 3-63 HCO paper jam indication
1. 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
Offline
Offline
Menu End
600dpi
LTR
LTR
LTR
Offline
Blinking
HCO jam 1
PCL
Cen
Clearing Paper Output Jams
3-46 Printer Tasks
2. 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.
Figure 3-65 HCO Knob 1 Paper Input Roller
3. Pull lever 2 back (Figure 3-66) and remove any paper.
Figure 3-66 Clearing HCO lower section paper jam using Lever 2
HCO Knob 1
HCO
Lever 2
Clearing Paper Output Jams
Printer Tasks 3-47
Printer Tasks
4. 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. Close the HCO door.
6. 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.
HCO Lever 1
Clearing Paper Output Jams
3-48 Printer Tasks
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.
Figure 3-68 Separating HCO and printer
2. Figure 3-69 shows detailed look at the connecting pin and the positioning hole.
Figure 3-69 Printer connecting pin and HCO positioning hole configuration
Connecting
Pin
Bracket B Bracket A
Positioning
Hole
Printer HCO
Pin
Printer Push HCO
left to disengage
Unscrew Bracket A
Pin
Pull HCO away from printer
Handling Error Messages and Troubleshooting
Printer Tasks 3-49
Printer Tasks
3. Unscrew bracket A, which connects the HCO to the printer.
4. Push the HCO to the left to disengage the connecting pin from the positioning hole.
5. 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.
6. Push the HCO and the printer together and reseat the connecting pin in the positioning
hole.
7. 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
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.
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.
Figure 3-70 Error reporting
Error message
Action message
PCL 12.145
Cen
Clear Custom
Offline
Menu Test PapSize
600dpi
LTR
LTR
LTR
Online
Close front door
Front door open
Handling Error Messages and Troubleshooting
3-50 Printer Tasks
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. The printer may self-diagnose the problem and possibly display the message as shown in
Figure 3-71.
2. Write down the error code and message that appears on the Control Panel.
3. Refer to “Call Engineer Error Messages and Codes” on page A-8 to determine the
meaning of the error code.
4. If the error code calls attention to a specific physical component or location on the
printer, check the area specified and correct the problem.
5. 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.
Figure 3-71 Call Engineer (Service Representative)
Clear
Offline
Menu End
LTR
LTR
LTR
Offline
High-voltage power supply alarm
Call Engineer (SVC 6F)
PCL
Blinking
Error code
Ordering and Replacing Consumables 4-1
Consumables
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 page 4-1
• To order additional consumables page 4-2
• To replace toner or recycle toner after replacement page 4-4
• To replace developer and ozone filter page 4-9
• To replace the drum and transfer assembly page 4-18
• To replace the fuser page 4-29
• To replace the printer pick rollers page 4-33
• To replace the HCI pick rollers 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 Damage to the photoconductor can cause excessively light or dark printing or
missing text.
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 D640 Printer Consumables
4-2 Ordering and Replacing 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.
Ordering D640 Printer Consumables
Ordering and Replacing Consumables 4-3
Consumables
Table 4-1 Consumables, product part numbers, and replacement cycles
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.
Item Product
Number Contents Qty Replacement Cycle
(Estimated) Shelf
Life
Toner Kit C5626A Toner bottles 8 each Up to 180,000 page sides
Note: Yield based on 4%
toner coverage
18 months
Collector bottles 8 each
Cleaning rollers 4 each
Developer Kit C5632A Developer bottles 2 each Up to 250,000 page sides 18 months
Ozone filter 1 each
Drum Kit C5629A Photoconductor
drum 1 each Up to 195,000 page sides 18 months
Transfer unit 1 each
Cleaning wipes 1 pkg
Fuser Kit C5627A Fuser, 120-127 VAC 1 each Up to 300,000 page sides 18 months
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 Inf.
HCI Pick
Roller Kit C5636A HCI pick rollers 1 set Up to 500,000 pages
Note: Replacement cycles based on letter or A4 sized media. Larger sized media require more frequent
replacement.
Replacing Toner
4-4 Ordering and Replacing Consumables
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. Press Offline.
2. Open the upper right cover (Figure 4-1) to access the toner hopper and toner collector
bottle.
Figure 4-1 Opening Upper Right Cover
Toner collector bottle
Toner hopper
Upper right cover open
..
..
....
.
..
.
.
.....
Replacing Toner
Ordering and Replacing Consumables 4-5
Consumables
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. Locate the toner kit.
4. Remove a toner bottle.
5. Open the toner fill flap (front flap), as shown in Figure 4-2.
Figure 4-2 Opening the Toner Fill Flap and shaking the Toner Bottle
6. 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.
7. 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.
Toner fill flap
Replacing Toner
4-6 Ordering and Replacing Consumables
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. When empty, turn the toner bottle counterclockwise 180° and remove, as shown in
Figure 4-3.
9. Close the toner fill flap, as shown in Figure 4-4.
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.
Handle
Guide pin
Toner bottle
Empty toner bottle
Toner fill flap
Replacing Toner
Ordering and Replacing Consumables 4-7
Consumables
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.
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.
1. Open the front door.
2. Pull out the old cleaning roller, as shown in Figure 4-6.
Pull out old bottle
Insert new bottle
Replacing Toner
4-8 Ordering and Replacing Consumables
Figure 4-6 Removing the Cleaning Roller
3. Insert the new cleaning roller until it clicks into place, as shown in Figure 4-7.
Figure 4-7 Inserting the Cleaning Roller
Cleaning roller
LTR
Cleaning roller
LTR
Replacing Developer
Ordering and Replacing Consumables 4-9
Consumables
4. Close the front door.
5. 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. Discharge old developer.
2. Add new developer. (“Adding New Developer” on page 4-12).
3. 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.
Figure 4-8 Menu
Online
Menu
Online
Printing
Configuration
PCL
Comms
Maintenance
Replacing Developer
4-10 Ordering and Replacing Consumables
2. Use N to highlight Maintenance, as shown in Figure 4-9.
Figure 4-9 Maintenance
3. Use P to display Maintenance selections as shown in Figure 4-10.
Figure 4-10 Maintenance selections
4. Use P to display replace selections, as shown in Figure 4-11. Developer is shown
selected.
Figure 4-11 Replace selections
Online
Menu
Online
Printing
Configuration
PCL
Comms
Maintenance
Online
Maintenance
Online
replace
alignment
density = 10
testpages = 30
monitor = OFF
date-time
Online
Maintenance.replace
Online Select
DEVELOPER
DRUM UNIT
FUSER UNIT
TRAY1ROLLERS
TRAY2ROLLERS
TRAY3ROLLERS
Replacing Developer
Ordering and Replacing Consumables 4-11
Consumables
5. Press Select to display Developer instructions, as shown in Figure 4-12.
Figure 4-12 Discharge Developer
6. Press Start, as shown in Figure 4-12.
7. 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.
Figure 4-13 Developer discharging
Start Exit
LTR
LTR
LTR
Developer Replacement
Prepare new developer
and press Start
to discharge old developer
Online
Developer discharge
Developer discharging
Please Wait
Blinking
Replacing Developer
4-12 Ordering and Replacing Consumables
8. After 45 seconds, you see the display shown in Figure 4-14.
Figure 4-14 Developer discharge complete
9. Press Done.
Adding New Developer
1. Open the upper right cover and locate the developer bottle as shown in Figure 4-15.
Figure 4-15 Developer and Developer Collector Bottle
Online
Blinking
Done
Developer discharge completed
Prepare new developer bottle
Open upper right cover
Press Done
Developer collector bottle
Upper right cover
..
..
....
.
..
.
.
.....
Replacing Developer
Ordering and Replacing Consumables 4-13
Consumables
2. Remove the developer collector bottle, as shown in Figure 4-16.
Figure 4-16 Removing Developer Collector Bottle
3. Move the bottle cap from the storage position onto the collection hole to close the bottle,
as shown in Figure 4-16.
4. Discard the developer collector bottle. The developer collector bottle is made of
recyclable materials; dispose of it in accordance with local regulations.
5. The following text appears on the Control Panel:
Developer injection
Open rear flap
Insert New Developer bottle
Press Done when bottle empty
6. Locate a new bottle of developer.
Replacing Developer
4-14 Ordering and Replacing Consumables
7. Open the developer fill flap, as shown in Figure 4-17.
Figure 4-17 Opening the Developer Fill Flap
Caution Never reinstall used developer. Doing so may result in poor print quality.
8. 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.
Figure 4-18 Filling the Developer and tapping the Developer Bottle
Developer fill flap
Developer bottle
Guide pin
Guide pin slot
Developer bottle
Replacing Developer
Ordering and Replacing Consumables 4-15
Consumables
9. 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.
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:
Developer injection complete
Remove and Cap Old Bottle
Install Empty New Bottle
Close Cover and Press Done
Empty developer bottle
Replacing Developer
4-16 Ordering and Replacing Consumables
Installing Developer Collector Bottle
1. Remove small cap on the side of the developer collector bottle.
2. Turn cap around and place in the storage location, as shown in Figure 4-20.
Figure 4-20 Installing Developer Purge Bottle
3. 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. Close upper-right cover.
5. Press Done on the Control panel.
Empty bottle
Replacing Developer
Ordering and Replacing Consumables 4-17
Consumables
Replacing the Ozone Filter
Replace the ozone filter after every other developer replacement.
1. Locate the ozone filter packaged in the Developer Kit.
2. Remove the used filter from the filter holder and install the new one, as shown in
Figure 4-21.
Figure 4-21 Replacing the Ozone Filter
3. Discard the used filter. The filter is not made of recyclable materials; dispose of it in
accordance with local regulations.
Ozone filter
Handle
Ozone filter holder
Handle
Drum Kit - Replacing Drum and Transfer Assembly
4-18 Ordering and Replacing Consumables
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. Press the Menu button on the Main Screen.
2. Press N to highlight Maintenance.
3. Press P to display Maintenance selections.
4. Press P to enter the Replace submenu.
5. Press N to highlight DRUM UNIT.
6. Press P to display drum instructions as shown in Figure 4-22.
Figure 4-22 Replace Drum
Online
Drum Replacement
Replace Drum unit
and Press Done
Done
Drum Kit - Replacing Drum and Transfer Assembly
Ordering and Replacing Consumables 4-19
Consumables
Removing the Transfer Assembly
1. Open the front door, if it is not already open.
2. While pulling Handle 3, carefully lower the transfer guide as shown in Figure 4-23.
Figure 4-23 Handle 3 and Transfer Assembly Guide
Transfer assembly
guide
Handle 3
LTR
Drum Kit - Replacing Drum and Transfer Assembly
4-20 Ordering and Replacing Consumables
3. 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.
Figure 4-24 Removing the Transfer Assembly
4. Discard the transfer unit.
Transfer assembly
Wire
Transfer assembly guide
LTR
Transfer assembly
Transfer assembly guide
Pin
Drum Kit - Replacing Drum and Transfer Assembly
Ordering and Replacing Consumables 4-21
Consumables
Removing the Drum
1. Turn drum locking knob counterclockwise two or three turns to unlock the drum, as
shown in Figure 4-25.
Figure 4-25 Releasing the Drum
LTR
Twist thumbscrew
Handle 3
Lever b1
Drum Kit - Replacing Drum and Transfer Assembly
4-22 Ordering and Replacing Consumables
2. Rotate Lever b1 clockwise, as shown in Figure 4-26.
3. Use the drum handles on the top and front to pull it out, as shown in Figure 4-26.
Figure 4-26 Removing the Drum
4. Discard the used drum. The drum is an aluminum cylinder coated with non-hazardous
organic material. Dispose of it according to local ordinances.
Top handle Guide rails
Front handle
Lever b1
Drum Kit - Replacing Drum and Transfer Assembly
Ordering and Replacing Consumables 4-23
Consumables
Unpacking the New Drum
1. Open the vacuum sealed bag containing the drum and remove it, as shown in
Figure 4-27.
Figure 4-27 Unpacking Drum and removing the Protective Cover
2. 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.
Caution Do not touch the surface of the drum. Finger prints and scratches on the surface of
the drum may adversely affect print quality.
Drum
Drum Kit - Replacing Drum and Transfer Assembly
4-24 Ordering and Replacing Consumables
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.
Figure 4-28 Inserting the Drum
Top handle Guide rails
Drum alignment
pins
Front handle
Alignment
pin holes
Lever b1
Drum Kit - Replacing Drum and Transfer Assembly
Ordering and Replacing Consumables 4-25
Consumables
2. Gently push the drum onto the positioning pins (Figure 4-29).
Figure 4-29 Drum Alignment Pin locations
Note Make sure the alignment pins on the printer line up with the alignment-pin holes on the
drum.
(2) Drum Alignment Pins
Drum Kit - Replacing Drum and Transfer Assembly
4-26 Ordering and Replacing Consumables
3. 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.
Figure 4-30 Securing the Drum
4. Rotate Lever b1 counterclockwise to lock the drum in place.
Drum locking knob
LTR
Drum Kit - Replacing Drum and Transfer Assembly
Ordering and Replacing Consumables 4-27
Consumables
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.
Figure 4-31 Inserting the Transfer Assembly into the Guide
Transfer assembly
Wire
Transfer assembly guide
LTR
Transfer assembly
Transfer assembly guide
Pin
Drum Kit - Replacing Drum and Transfer Assembly
4-28 Ordering and Replacing Consumables
3. Secure the transfer assembly guide by lifting Handle 3 until it snaps into place as shown
in Figure 4-32.
Figure 4-32 Securing the Transfer Assembly
4. Close the front door.
5. Use the drum kit packing materials to repack for disposal.
Handle 3
Transfer assembly
guide
LTR
Fuser Kit - Replacing the Fuser
Ordering and Replacing Consumables 4-29
Consumables
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 This procedure is applicable to both 120-127 VAC and 200-240 VAC fusers.
1. Press the Menu button on Main Screen.
2. Press N to highlight Maintenance.
3. Press P to display Maintenance selections.
4. Press P to display replace selections
5. Press N to select fuser.
6. Press Select to display fuser instructions, as shown in Figure 4-33.
Figure 4-33 Fuser instructions
Online
Fuser unit Replacement
Replace Fuser unit and
Press Done
Done
Fuser Kit - Replacing the Fuser
4-30 Ordering and Replacing Consumables
Removing the Fuser
To remove the fuser:
1. Open the front door.
2. Turn the fuser locking knob counterclockwise several times to release the fuser, as
shown in Figure 4-34.
Figure 4-34 Releasing the Fuser Locking Knob
WARNING! The fuser may be hot. Avoid touching the fuser surfaces labeled as hot.
3. Pull the fuser out, supporting it with your hand, as shown in Figure 4-35.
Figure 4-35 Pulling the Fuser out
LTR
Fuser locking knob
Fuser
LTR
Fuser Kit - Replacing the Fuser
Ordering and Replacing Consumables 4-31
Consumables
Installing the Fuser
1. Locate and remove the new fuser from its packaging.
2. 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.
Figure 4-36 Installing the Fuser
Fuser
Fuser Kit - Replacing the Fuser
4-32 Ordering and Replacing Consumables
3. 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.
Figure 4-37 Fuser Locking Knob and Decurler Roller Knob
4. Verify all locks and levers are secure and then close the front door.
5. Press Done.
Decurler roller knob
Fuser locking knob
Printer Pick Roller Kit - Replacing the Tray Pick Rollers
Ordering and Replacing Consumables 4-33
Consumables
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. Press the Menu button on the Main Screen.
2. Press N to select Maintenance.
3. Press P to select Maintenance options.replace should be highlighted.
4. Press Select to enter the replace submenu.
5. Press N to select the set of tray rollers to be replaced.
6. 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.
Figure 4-38 Removing Paper Trays - all trays removed
Tray3
Tray1
Tray2
Pick rollers
Pick rollers
Pick rollers
Printer Pick Roller Kit - Replacing the Tray Pick Rollers
4-34 Ordering and Replacing Consumables
2. Locate the thumb screw holding the steel plate over the lower tray roller assembly, as
shown in Figure 4-39.
Figure 4-39 Locating Thumbscrew
3. 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
Thumbscrew
Printer Pick Roller Kit - Replacing the Tray Pick Rollers
Ordering and Replacing Consumables 4-35
Consumables
4. 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
5. Pull the two lower rollers off of the lower shaft now. See Figure 4-42.
Figure 4-42 Removing Lower Rollers from Shaft
Printer Pick Roller Kit - Replacing the Tray Pick Rollers
4-36 Ordering and Replacing Consumables
6. 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
7. Pull the upper roller assembly off of the upper shaft, as shown in Figure 4-44.
Figure 4-44 Removing Upper Roller Assembly
Printer Pick Roller Kit - Replacing the Tray Pick Rollers
Ordering and Replacing Consumables 4-37
Consumables
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.
Figure 4-46 Installing Torque Limiter
Printer Pick Roller Kit - Replacing the Tray Pick Rollers
4-38 Ordering and Replacing Consumables
1. 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.
Figure 4-47 Correct Torque Limiter placement
2. 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.
Figure 4-48 Correct Larger Lower Roller placement
Notch correctly positioned to go
over metal peg Roller correctly installed all the way,
with notch over the metal peg
Larger lower roller positioned on the
same shaft as the smaller roller
Larger lower roller rotated to
engage plastic pegs on smaller
Printer Pick Roller Kit - Replacing the Tray Pick Rollers
Ordering and Replacing Consumables 4-39
Consumables
3. 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.
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.
Figure 4-50 Upper Pick Roller Assembly Slot and Mounting Tooth on printer
Blue clip placed on lower
roller shaft Blue clip snapped into place on
lower roller shaft groove
Slot
Metal tooth
Printer Pick Roller Kit - Replacing the Tray Pick Rollers
4-40 Ordering and Replacing Consumables
4. Install the new upper pick roller assembly over the shaft. See Figure 4-51.
Figure 4-51 Installing Upper Roller Assembly
5. 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.
6. 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
Printer Pick Roller Kit - Replacing the Tray Pick Rollers
Ordering and Replacing Consumables 4-41
Consumables
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
2. Replace the three paper trays back into the printer, as shown in Figure 4-54.
Figure 4-54 Installing Paper Trays
3. Press Done on the Control Panel.
4. Perform the Paper Path Alignment procedure described in “Adjusting Paper Path
Alignment” on page 6-11.
HCI Pick Roller Kit - Replacing the HCI Pick Rollers
4-42 Ordering and Replacing Consumables
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. Press the Menu button on the Main Screen.
2. Press N to select Maintenance.
3. Press P to select Maintenance options. replace should be highlighted.
4. Press Select to enter the replace submenu.
5. Press N to select the HCI tray rollers. The HCI option only appears if the HCI is
installed.
6. 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.
Figure 4-55 Sliding HCI away from printer
LTR
LTR
LTR
HCI Pick Roller Kit - Replacing the HCI Pick Rollers
Ordering and Replacing Consumables 4-43
Consumables
2. 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.
Figure 4-56 Opening the HCI
3. 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.
Figure 4-57 HCI Rear and Lower Roller Assembly Springs
LTR
LTR
LTR
HCI Pick Roller Kit - Replacing the HCI Pick Rollers
4-44 Ordering and Replacing Consumables
4. 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
5. 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
HCI Pick Roller Kit - Replacing the HCI Pick Rollers
Ordering and Replacing Consumables 4-45
Consumables
6. 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
7. 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.
Figure 4-61 Unscrew Thumbscrews and remove
HCI Pick Roller Kit - Replacing the HCI Pick Rollers
4-46 Ordering and Replacing Consumables
8. 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
HCI Pick Roller Kit - Replacing the HCI Pick Rollers
Ordering and Replacing Consumables 4-47
Consumables
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
1. From the front of the HCI, gently guide the upper roller assembly into place, as shown in
Figure 4-65.
Figure 4-65 Installing Upper Roller Assembly
HCI Pick Roller Kit - Replacing the HCI Pick Rollers
4-48 Ordering and Replacing Consumables
2. 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
3. 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
HCI Pick Roller Kit - Replacing the HCI Pick Rollers
Ordering and Replacing Consumables 4-49
Consumables
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
2. 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.
Figure 4-69 Installing Clip onto Lower Roller Assembly
HCI Pick Roller Kit - Replacing the HCI Pick Rollers
4-50 Ordering and Replacing Consumables
3. 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
4. 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.
Figure 4-71 Closing the HCI Door
5. Press Done on the Control Panel.
6. Perform the Paper Path Alignment procedure described in “Adjusting Paper Path
Alignment” on page 6-11.
LTR
LTR
LTR
Maintenance 5-1
Maintenance
5
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.
Weekly Cleaning
5-2 Maintenance
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. Turn off the main power switch, and open the upper right cover.
2. 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 Cleaning Toner Hopper area
3. Close the upper right cover.
Weekly Cleaning
Maintenance 5-3
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.
Figure 5-2 Cleaning the Precharger
2. Push the precharger cleaner in completely.
Precharger cleaner
Weekly Cleaning
5-4 Maintenance
Paper Feed Area
To clean the paper feed area, follow these steps:
1. Open the lower right cover.
2. 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
3. Close the lower right cover.
Paper Input Trays
To clean the inside of the paper input trays, follow these steps:
1. Remove tray3 from the printer, then remove any paper in it.
2. Use the vacuum cleaner to remove any paper dust or chips from the tray.
3. Reinstall the paper in the tray, and the tray in the printer.
4. Repeat steps 1 - 3 for the other two trays.
Periodic Cleaning (When Replacing Drum)
Maintenance 5-5
Maintenance
Printer Exterior
1. Check the paper output tray on top of the printer and use the vacuum to remove any
paper dust or dirt.
2. 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. Turn the main power switch off, and open the front door.
2. Hold lever 5 to the left to open the reversing unit area. See Figure 5-4.
3. 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
Periodic Cleaning (When Replacing Drum)
5-6 Maintenance
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 Cleaning Duplex Area
2. Lower lever 6 to close the duplex unit.
3. 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. 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.
2. 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.
Periodic Cleaning (When Replacing Drum)
Maintenance 5-7
Maintenance
Figure 5-6 Handle 3 and Transfer Assembly Guide
3. Push in and pull up on the transfer assembly to free it from the guide assembly, as shown
in Figure 5-7.
Figure 5-7 Removing the Transfer Assembly
Handle 3
Transfer assembly
Wire
Transfer assembly guide
LTR
Transfer assembly
Transfer assembly guide
Pin
Periodic Cleaning (When Replacing Drum)
5-8 Maintenance
4. 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 Cleaning the Transfer Assembly
Periodic Cleaning (When Replacing Drum)
Maintenance 5-9
Maintenance
Transfer Assembly Guide
To clean the Transfer Assembly Guide:
1. Take out the drum unit (refer to “Removing the Drum” on page 4-21.)
2. 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
Periodic Cleaning (When Replacing Drum)
5-10 Maintenance
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
2. Install the new drum assembly, as described in “Drum Kit - Replacing Drum and
Transfer Assembly” on page 4-18.
Periodic Cleaning (When Replacing Drum)
Maintenance 5-11
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.
Figure 5-11 Inserting the Transfer Assembly into the guide
Transfer assembly
Wire
Transfer assembly guide
LTR
Transfer assembly
Transfer assembly guide
Pin
Periodic Cleaning (When Replacing Drum)
5-12 Maintenance
2. Secure the transfer assembly by lifting Handle 3, as shown in Figure 5-12.
Figure 5-12 Securing the Transfer Assembly
3. Close the front door.
Note If you have problems reinstalling the transfer assembly, check to see that the drum is
installed correctly.
Handle 3
Transfer assembly
guide
LTR
Advanced Topics 6-1
Advanced Topics
6
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. Complete all of the weekly maintenance tasks (see “Weekly Cleaning” on page 5-1).
2. Clean your printer thoroughly (see “Periodic Cleaning (When Replacing Drum)” on
page 5-5).
3. Check the quality of your prints.
Maintaining Print Quality
6-2 Advanced Topics
If you are still dissatisfied with your print quality:
1. 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 prob-
lem effects and not the actual print pattern.
2. Generate test prints to compare with the quality samples. (See Appendix E for more
information.)
3. Identify a print quality sample included in this section that has the same flaws as your
print test.
4. 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.
5. 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. 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.
2. Check whether the paper being used meets Hewlett-Packard standards. (Refer to “Using
Paper” on page D-1.)
3. Check whether the paper is handled correctly (especially for creases or wrinkles).
4. 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”.
5. Check whether the rollers and the paper guides are clean (especially for scattered toner
or developer, accumulated paper powder and paper pieces).
6. Check the Economode setting; be sure it is OFF. (See “Economode” on page 2-17.)
7. Adjust the print density. (See “Density” on page 2-25.)
Maintaining Print Quality
Advanced Topics 6-3
Advanced Topics
Good Quality Print Sample
Figure 6-1 Good quality print sample
Maintaining Print Quality
6-4 Advanced Topics
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 “Econo-
mode” 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 den-
sity. (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 pre-
charger. (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 autho-
rized 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 autho-
rized HP service representative.
Maintaining Print Quality
Advanced Topics 6-5
Advanced Topics
Lines
If sharp or smeared black streaks appear on the page (in the
direction the paper passes through the printer):
• Toner may be on the transfer charger or pre-charger corona
wires. Clean the printer’s transfer assembly unit and pre-
charger. (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 autho-
rized 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 autho-
rized 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 den-
sity (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 pre-
charger. (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 autho-
rized HP service representative.
Managing Consumables
6-6 Advanced Topics
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. 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.
2. 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.
3. 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.
4. Use the toner management features discussed on page 6-7. The D640 printer supports
several features that maximize toner usage.
5. 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.
6. 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.
7. 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.
8. 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.
Managing Consumables
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.
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 text-
only 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.
Managing Consumables
6-8 Advanced Topics
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.
Managing Consumables
Advanced Topics 6-9
Advanced Topics
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.
Toner Recycle Slide
Managing Consumables
6-10 Advanced Topics
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.