Download: User Manual Model D640 (Printer and Accessories)

HP 5000 Cut Sheet Printers

User Manual Model D640

(Printer and Accessories),

HP 5000 D640 Cut Sheet Printer User Manual

(Printer and Accessories) Hewlett-Packard Company C5620-90024 E0397,

Notice

Hewlett-Packard makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Hewlett-Packard shall not be liable for errors contained herein or for incidental or 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 ii,

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. iii,

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. iv, 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. v,

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. vi,

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 vii,

Table of Contents

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 ix, 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 x, 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 xi, 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 xii, 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 xiii,

B Host Serial and Parallel Interface Configuration

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

C Specifications and Regulatory Information

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

D Using Paper

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

E Printing Reports

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

About Your Printer About Your Printer

Figure 1-1 D640 with High Capacity Input and High Capacity Output installed

Standard Features of the D640 Printer

• 600 x 600 dpi resolution • 40 page per minute printing (simplex) • Duplex printing from A5 to Ledger size paper, plus custom sizes • Prints forms, pre-punched, labels, and transparency media • Standard paper input capacity of 1500 sheets (three paper trays) • 16 MB of memory, expandable to 64 MB • Hewlett-Packard LaserJet printer compatibility • EconoMode for reducing toner expense • Microfine toner About Your Printer 1-1, Accessories For the D640 Printer • Toner recycling • Virtual Font Cartridges resident on internal hard disk • Operator-replaceable consumables (toner, developer powder, drum, fuser, and paper pick rollers) • Bitronics parallel and serial interfaces with automatic switching • PCL 5e, PJL, and HP-GL/2 language support built in • IEEE 1284C support for 10 meter parallel cables • Energy Star compliance

Accessories For the D640 Printer

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

Full 600 x 600 Resolution

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

Rugged Construction for Long Life

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

Consumable Replacement and Tracking

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

Duplex Printing With No Performance Degradation

The D640 performs duplex printing (letter and A4 paper sizes) at 40 page sides per minute. 1-2 About Your Printer, Accessories For the D640 Printer

About Your Printer Toner Recycling and Economy Mode Printing

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

High Capacity Paper Handling

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

Custom Paper Size Support

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

Backlit LCD Display

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

Multiple Interfaces

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

PostScript Level 2

PostScript is available for the D640 as an add-on product and includes an additional 16 megabytes of memory. The printer can be configured to automatically switch between PostScript and PCL print jobs. About Your Printer 1-3, Accessories For the D640 Printer

Compatibility with LaserJet 4Si/5Si Printer

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

PCL Level 5e

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

Integral Hard Disk

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

Energy Star Compliance

To help minimize power consumption, the D640 complies with the Energy Star Program of the U.S. Environmental Protection Agency. Note If you have not done so, please refer to the Installation Manual and complete the installation procedures. These procedures ensure the safe operation of the printer and the best print quality. The printer requires regular maintenance, as described later in this manual. Although maintenance takes only a few minutes weekly, it is very important to the quality of the printouts and the life of the printer. Caution Hewlett-Packard recommends the use of Hewlett-Packard labelled consumable supplies. Hewlett-Packard is not responsible for any failures or print quality issues arising from the use of other than Hewlett-Packard supplies. Such failures are not covered under warranty or by any Hewlett-Packard service agreement. 1-4 About Your Printer, Getting to Know the Printer

About Your Printer Getting to Know the Printer Orientation

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

LTR LTR LTR

HCO D640 HCI Printer Figure 1-2 D640 with High Capacity Input and High Capacity Output About Your Printer 1-5, Getting to Know the Printer

The D640 Printer

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

ON

*Speaker Control panel Function buttons Screen contrast control Standby switch Ejection unit Paper output tray Front cover ... Front door Upper right cover Tray1 Tray2 Tray3 Lower right cover Paper size indicators Paper level indicators Main power switch * Not used Figure 1-3 Front and right side of the printer ... .. ... .. .. .. ..1-6 About Your Printer, Getting to Know the Printer

About Your Printer Front and Right Side of the Printer

In Figure 1-3, starting at the Control Panel at the top left and reading clockwise, refer to the following points of interest. • Control Panel: Consists of function buttons and a liquid crystal display (also referred to as the LCD panel) that presents messages about printer activity. • Screen contrast control: Allows you to adjust the contrast of the display. • Ejection unit: Deposits paper to the output tray. • Standby switch: Powers the printer on and off. • Output tray: Holds printed pages. • Upper right cover: Provides access to add toner and developer. • Lower right cover: Provides access to the paper path (for jam clearing) from the paper trays. • Paper indicators: Provide a visual gauge for the size and relative amount of paper in each tray. • Main power switch: Applies line voltage to the printer. • Trays 1, 2, and 3: These are the input paper trays for standard size media. You can also obtain and install optional adjustable custom trays that hold custom (or standard) sizes of paper. • Front door: Provides access to the printer’s interior. • Front cover: Provides access to the printer’s floppy disk drive for installing PostScript and PCL code updates. About Your Printer 1-7,

Getting to Know the Printer

PC card slot * ... .. ..... ... Serial diagnostic port * Floppy disk drive Front cover

LTR LTR LTR

* For support use only.

Figure 1-4 Behind the front cover

1-8 About Your Printer, Getting to Know the Printer

About Your Printer Behind the Front Cover

The front cover is located below the Control Panel, as shown in Figure 1-4. When you open it, you find the following: • PC card slot: Used only for support testing, and covered with a rubber protective cap. • Serial diagnostic port: Used only for testing. • Floppy disk drive: Used for updating printer functions and installing the PostScript upgrade. About Your Printer 1-9,

Getting to Know the Printer

... Fuser locking knob Fuser unit Drum unit locking knob Precharger cleaner Cleaning roller Drum unit Lever 5 Decurler roller knob Lever b1 Knob 2 Decurler lever Lever 4 Knob 1 Duplex unit Duplex roller knob

L

Handle 3 TR Lever 6 Transfer assembly guide

Figure 1-5 Behind the front door

1-10 About Your Printer, Getting to Know the Printer

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. About Your Printer 1-11, Getting to Know the Printer Install toner here Install developer here ... .. ...... Toner collector bottle Developer collector bottle Toner hopper Developer unit Upper right cover Figure 1-6 Behind the upper right cover 1-12 About Your Printer, Getting to Know the Printer

About Your Printer Behind the Upper Right Cover

By opening the upper right cover, you gain access to the printer’s consumables, as shown in Figure 1-6 and described below. • Toner hopper: A reservoir that holds toner. The Control Panel displays messages to indicate toner low and toner empty status. Never add toner before the printer indicates that toner is needed. • Developer unit: holds the developer mixture that prepares toner for transfer to the photoconductor drum. • Developer collector bottle: Collects used developer for disposal. • Toner collector bottle: Collects waste toner for disposal. Note Never pour waste toner into the toner hopper. If you do not want to discard waste toner, use the toner recycling feature described in “Toner Recycling Switch” on page 6-8. Caution Never re-use developer. Severe print quality problems and physical damage may occur if you do so. About Your Printer 1-13,

Getting to Know the Printer

Serial port (RS232/422) Switches used for support only Ejection unit Parallel port (IEEE 1284C) Upper left cover Paper side exit (under cover) User documentation holder Ozone filter HCO attachment points (under covers) HCI connector AC input power connector HCO connector Lower connector not used

Figure 1-7 Rear and left side of the printer

1-14 About Your Printer, Getting to Know the Printer

About Your Printer Rear and Left Side of the Printer

The rear of the printer has the features shown in Figure 1-7 and described below. • Ozone filter: Absorbs and reduces the printer’s ozone emissions. • Documentation holder: Provides a convenient location to store the printer manuals. • Parallel port: Supports IEEE 1284C bidirectional host interconnections. • Serial port: Supports RS232/422 host interconnections. • Ejection unit: Provides access to clear paper jams in this area. • Paper Side Exit (under cover): Provides access to the external paper path opening. • HCO connector: Used to control the optional HCO stacker. • Lower connector: Reserved for future accessories. • AC input power connector: Accepts either 120-127 or 200-240 VAC input power (fuser must be matched to the input voltage). • HCI connector: Used to control the optional HCI feeder. About Your Printer 1-15, Getting to Know the Printer

High Capacity Input Accessory

An optional High Capacity Input (HCI) accessory (shown in Figure 1-8) is available to provide an additional input capacity of 3000 sheets. The HCI sits on rails attached to the printer and is electrically connected to the printer by a cable, and obtains its power from the printer. The HCI highlights are: • HCI release handle: When squeezed, detaches the HCI from the printer. • Paper table lowering button: When pressed, lowers the table for paper replenishment. The printer must be powered on with all covers closed, or the table will not lower. • HCI door: Allows visual inspection of the paper supply. • Door handle: Provides easy access to the paper supply. • Elevator-type movable table: Supports the paper supply. HCI release handle Paper table lowering button HCI door Door handle Printer Paper table (inside door) 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.) 1-16 About Your Printer, Getting to Know the Printer

About Your Printer High Capacity Output Accessory

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

ON OFF

HCO Interface Main Power Switch control cable Input power cord connector Figure 1-9 High Capacity Output accessory About Your Printer 1-17, Powering On the Printer

Powering On the Printer

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

ON

... Standby switch

ON OFF

Main power switch Figure 1-10 Standby switch and Main power switch 2. 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. Screen contrast control Standby switch

MODE

L 5 D0 640 00

ON

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... .... ..1-18 About Your Printer,

Control Panel 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 Control Panel 2-1, Getting to Know the Control Panel

Getting to Know the Control Panel

LCD panel PowerSave indicator Standby switch ..... .. ..

ON

Speaker (not used) Function buttons Screen contrast control Figure 2-1 Control Panel

Control Panel Features and Functions

The Control Panel is one of the means to control and configure the printer. Through the Control Panel, the printer displays information about aspects of normal operation, paper jams, consumable status, and error conditions. Use the function buttons on the Control Panel to change printer settings. Control Panel features include: • The Standby switch turns the printer on and off: - When you move the Standby switch momentarily to the ON (or up) position, the printer powers on. There will be up toa2minute delay before you can print while the printer performs an initialization sequence and warms the fuser to operating temperature. - When you move the Standby switch momentarily to the OFF (or down) position, the printer is powered off and placed in Standby mode. There may be a delay in the printer powering off; any pages currently moving through the paper path are printed before the printer powers off. • The Screen contrast control adjusts the contrast of the LCD panel. • The Function buttons are located below the LCD panel. These five buttons perform different functions during printer operations, such as when the printer is printing, or when you are changing settings. Figure 2-6 shows these function buttons. 2-2 Control Panel, Checking Printer Status

Control Panel

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

Checking Printer Status

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

Normal Printer Status (No Error Condition Displayed)

The message field of the display shown in Figure 2-2 reports the D640’s status. Ready - - free 600dpi JUN 18 05:32.23 Message field

PCL LTR LTR

Ofnflliinee Printer is offline LTR Offline Custom Menu Test PapSize 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). Control Panel 2-3, Checking Printer Status • PCL Indicates that the printer is using PCL (Printer Control Language) emulation. • Online The printer is ready to print.

Abnormal Printer Status

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

PCL LTR LTR

Offliine LTR Clear Menu Test PapSize 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. Ejection unit cover open Close ejection unit cover

PCL LTR LTR

Onfflliine LTR Clear Custom Menu Test PapSize Figure 2-4 Problem status report 2-4 Control Panel, Checking Paper

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. Current paper path

Ready - - free 600dpi JUN 18 05:32.23 PCL LTR LTR LTR Onfflliine LTR Offline Custom Menu Test PapSize

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 LTR indicates that the tray contains letter size paper. The symbol indicates Letter the long edge is leading into the paper path and the filled-in symbol (LTR) indicates the tray has paper. Note: paper size determines whether the long or short edge leads into the paper path. A4 indicates that the tray is set to contain A4 size paper. The empty A4 symbol indicates the tray has no paper. Legal 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. (LGL) CUS indicates that custom paper is installed in the custom tray. This Custom particular custom tray paper configuration has the long edge leading into (CUS) the paper path. Control Panel 2-5, Function Buttons HCI HCI indicates that the HCI is installed and contains paper. Paper size can only be LTR or A4 (depending on the model of the HCI). A3 A3 indicates that A3 size paper is the specified paper size, but the missing symbol indicates that the tray is open. Table 2-1 lists all available standard paper categories and their respective sizes. Table 2-1 Standard paper sizes Category Dimensions 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)

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. Ready - - free 600 dpi JUN 18 05:32.23

PCL LTR

LTR LTR Onfflliine LTR Offline Custom Menu Test PapSize Commands for each button Function buttons Figure 2-6 Main Screen Function Buttons 2-6 Control Panel, Function Buttons

Control Panel

Table 2-2 Control Panel Main Screen Function Buttons Button Function Online/Offline toggles the printer from Offline to Online. Online When Online, the printer is ready to print. Online/ Offline Offline When Offline, the printer does not accept print requests. The printer goes

Offline Offline automatically when a paper jam or other detected problems occur. Online

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.

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. Menu Printing Configuration

PCL

Comms Maintenance

Online

Online Figure 2-7 Arrow Buttons Control Panel 2-7, Function Buttons Table 2-3 Control Panel Submenu Function Buttons M Press to scroll up the list of items on the submenu. N Press to scroll down the list of items on the submenu. P If an additional submenu is available, press this arrow to open the submenu. O Press to close a submenu and return to the previous menu level. Select Press to select the setting highlighted on the submenu. 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. Contination arrows tray1size = LETTER

LEGAL LEDGER EXECUTIVE A4 Online A5 Online Select

Figure 2-8 Continuation arrows Additional selection above Printing.copies 7

Online 12

Online Select Additional selections below Figure 2-9 Up and down continuation arrows 2-8 Control Panel, Custom Menu Settings

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: Custom Restore Save

Online

Online 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. Control Panel 2-9,

Custom Menu Settings

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.

Restore PwrOnConfig CUSTOM2 CUSTOM3 CUSTOM4 FACTORY Online Online Select Figure 2-11 Custom restore and save menu settings

This location stores settings used at power-on or from a job reset.

PwrOnConfig 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. 2-10 Control Panel, Printing Menu Settings

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. Menu Printing Configuration

PCL

Comms Maintenance

Online

Online 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) Sets the number of copies to be printed for each page. 32767 (maximum) =TRAY1 Sets the default media input source. TRAY2 Intray TRAY3 =HCI* (Default if HCI is present =auto Sets the default image the page will be formatted for.

LETTER LEGAL

LEDGER Auto uses the page size of the selected intray.

EXECUTIVE

Paper A4 A5 A3 JISB4 JISB5

CUSTOM

=UPPER Sets the media output destination. *Outbin HCO-FACEDOWN HCO-FACEUP Control Panel 2-11,

Printing Menu Settings Duplex =OFF Turns double-sided printing on or off. ON

=LONGEDGE Sets the duplex binding options. SHORTEDGE LONGEDGE (book) binding is the conventional side-to-side

Binding binding used in books.

SHORTEDGE (tablet) binding is the traditional top to bottom layout used with calendars. =none Lets you dedicate an input tray to be used for job separation TRAY1 sheets. "none" indicates that the job separation feature is not TRAY2 enabled. Job separation sheets are usually colored paper.

Jobseparate TRAY3 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 Enables the HCO offset (jogging) feature, which staggers ON finished jobs for easy separation. TRAY1 This setting redirects the HCI to act like tray1, tray2, tray3, or TRAY2 like itself. It is provided primarily to make the D640 HCI act TRAY3 just like an HP LaserJet IIIsi or 4si with an HCI, so jobs =HCI configured for a LaserJet print correctly on the D640 without modification. *HCI-Alias 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. Allows you to select the printer emulation protocol. The selections are: Auto - automatically selects PCL or PostScript* based on the print job data.

Emulation 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. =PORTRAIT Selects the print orientation. The figure below shows print LANDSCAPE orientation. REVPORTRAIT Reverse Reverse REVLANDSCAPE Portrait Landscape Portrait Landscape

Orientation ABC ABC ABC ABC

2-12 Control Panel,

Printing Menu Settings Control Panel

0.01 (minimum) Sets the number of lines per inch to print.

Lpi = 6.00

100.00 (maximum) =none The printer is capable of printing errors found while ERRORS processing a job. This works for PCL or PS jobs and is WARNINGS typically used to help troubleshoot a file which does not print correctly. The options are:

Error-Report 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.

Control Panel 2-13

, Configuration Menu Settings

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. Menu Printing Configuration

PCL

Comms Maintenance

Online

Online Figure 2-13 Configuration Menu Configuration newline =CR+LF traylock sizes =Confirm imageshift customsize Online units =1/720" Online 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. 2-14 Control Panel,

Configuration Menu Settings 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.

= CR + LF Sets the method of newline interpretation. Some files may

Newline CR contain carriage returns without line feeds, or line feeds LF without carriage returns. Use this setting to print such files

CR or LF properly. =tray1 Trays can be locked out of the automatic paper selection UNLOCKED process. Lock out paper trays if you don’t want the tray to be LOCKED available unless a job delivers a direct command to pick from =tray2 that tray. As an example, if you have a tray with letterhead in it, Traylock.tray UNLOCKED you may want to lock out this tray so that if the other two trays 1, 2, 3, and LOCKED ran out of paper, the letterhead would not automatically be =tray3 used. Locked trays are only selected if the print job contains HCI UNLOCKED the command to select the locked tray.

LOCKED

=*hciUNLOCKED

LOCKED

= CONFIRM This setting specifies how the printer behaves when it receives CONTINUE a request for a size of media not currently configured in the US printer. ISO 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.

Sizes 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.

Control Panel 2-15

,

Configuration Menu Settings

= -720(min) This setting allows you to incrementally adjust the top position 0 of the image on paper in units, an incremental adjustment. The 720(max) factory default unit scale is 1/720", but you can reset the unit

Imageshift.top 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. = -720(min) This setting allows you to incrementally adjust the left position 0 of the image on paper in units, an incremental adjustment. The 720(max) factory default unit scale is 1/720", but you can reset the unit

Imageshift.left 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. milli Unit Size Setting Range inch meter 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 = 2837(min) This setting configures the media size of nonstandard media. It 8417 is only used when you have a custom paper tray and one of the 8417(max) PapSize values is set to Cus(custom). The table below lists the

Customsize.width 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). milli Unit Size Setting Range customsize.width inch meter 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 2-16 Control Panel,

Configuration Menu Settings Control Panel

= 5155 (min) This setting specifies the width dimensions of custom paper. 12240 The table below lists the minimum and maximum custom paper

Customsize.height 12240(max) 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). milli Unit Size Setting customsize.height inch meter 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 1/100" Sets the unit values used in customsize and imageshift. 1/200"

Unit 1/300"1/600"

1/720"

MM

200 dpi Sets the print resolution for graphic images in dots per inch (dpi).

Dpi 300 dpi

=600 dpi OFF The D640 is able to print an image across the entire surface of the =ON 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 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. =ON When a paper jam occurs, the printer reprints all pages that did not Jamrecovery OFF 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. =OFF This setting specifies economy mode. When it is used for printing ON drafts, you can save up to 30 percent of your toner consumption. In

Economode 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.

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.

Control Panel 2-17

,

Configuration Menu Settings Economode

Ready - - free 600dpi JUN 18 05:32.23 PCL e

LTR LTR

Ofnflliinee LTR Offline Custom Menu Test PapSize

Figure 2-15 Economode

off This setting specifies the amount of time after the last print job 15 MIN before the printer enters PowerSave. When the printer enters Powersave 30 MIN PowerSave, it switches off the Control Panel backlight and lights =1 HR the green PowerSave indicator. Any activity on the printer serial or 2 HRS parallel interface or Control Panel buttons restores full power. 3 HRS =ENGLISH This setting specifies the language of text displayed on the Control FRANCAIS Panel and in reports under the test menu.

Language DEUTSCH ESPANOL ITALIANO

2-18 Control Panel, PCL Menu Settings

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. Menu Printing Configuration

PCL

Comms Maintenance

Online

Online Figure 2-16 PCL Menu PCL font =Courier symbolset =ROMAN8 8U pitch =10.00 pointsize =12.00 vcartridge1 =none Online vcartridge2 =none Online Figure 2-17 PCL Menu selections Control Panel 2-19,

PCL Menu Settings Font Sets the default character font.

Sets the default symbol set (character set) of the font specified in the font setting. A

Symbolset symbol set is a collection of letters, numbers, and symbols designed for specific

applications such as scientific equations and international language. Sets the default pitch size for the fixed-pitched font. Pitch is the number of characters that Pitch 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).

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.

Virtual The D640 has no slots to hold these cartridges. Instead, we provide the same

Font 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

Cartridges 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. = None 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

Vcartridge1 . the Font menu. Using vcartridge1 and vcartridge2 together, you

. can choose two font sets. Printer16 = None Sets the font cartridge used in virtual font cartridge 2.

Vcartridge2 .

. Printer16 2-20 Control Panel, Comms Menu Settings

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. Menu Printing Configuration

PCL

Comms Maintenance

Online

Online Figure 2-18 Comms Menu Comms timeout =15 databuffer =32 parallel serial

Online

Online Figure 2-19 Comms Menu selections Control Panel 2-21,

Comms Menu Settings

none Sets the time limit (in seconds) that the printer waits before ending an

Timeout =15 incomplete job or switching data ports (serial or parallel). When set to

300 (max) none, the printer waits for you to manually intervene. 1 (min) Sets the size of printer memory allocated for incoming data. Increasing =32 the data buffer size helps the host transfer data more quickly, but the 1000(max) printer has less memory to store pages for printing. Decreasing the data

Databuffer (in Kb) 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.

Printer initializing 600dpi Please Wait PCL Cen LTR LTR Ofnfline LTR Offline Custom Menu Test PapSize Figure 2-20 Incoming data processing bar

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.

Parallel 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). =baud This setting specifies the serial interface communication options. See below stopbits for an example of how these options are used together.

Serial parityflow

dtr levels 2-22 Control Panel, Comms Menu Settings

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. Control Panel 2-23, Maintenance Menu Settings

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. Menu Printing Configuration

PCL

Comms Maintenance

Online

Online Figure 2-21 Maintenance Menu Maintenance replace alignment density = 10 testpages = 30 monitor = OFF

Online date-time

Online Figure 2-22 Maintenance selections 2-24 Control Panel,

Maintenance Menu Settings Control Panel

The Replace selection initiates the replacement procedure

Replace 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, Sets the alignment correction values. See “Using Virtual Font Cartridges” on

tray2, tray3, hci, page 6-26 for the paper path alignment procedure. duplex, and duplexv 1 (min) This setting specifies the relative darkness of the print on a = 10 scale of 1 to 15, with 15 being the darkest setting. Gray scale 15 (max) patterns show the most visible effect. The effect of changing

Density Density can be seen immediately.

Note: The higher the density number, the quicker toner is used. To conserve toner, use a lower setting. cont Sets the number of pages printed when you print the

Testpages 1 (min) testpage in the Test menu. The cont selection causes printing = 30 to continue until you press End and select ABANDON.

30000 (max) = OFF Turns on a special area on the Control Panel which displays

Monitor ON printer registers. This should only be set to ON when directed

by your service provider for troubleshooting. minute =0-59 Sets the current date and time. The date and time is hour = 0-23 displayed on the Control Panel and printed on all test reports.

Date-Time date = 1-31month = JAN-DEC

year = (last 2 digits of year)

Control Panel 2-25

, PapSize Menu Settings

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. Ready - - free 600dpi JUN 18 05:32.23 Message field

PCL LTR LTR

Ofnflliinee Printer is offline LTR Offline Custom Menu Test PapSize Figure 2-23 PapSize Button PapSize tray1size =LETTER tray2size =LETTER tray3size =LETTER

Online

Online Figure 2-24 PapSize selections 2-26 Control Panel, PapSize Menu Settings

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. =LETTER Sets the paper size for tray1, tray2, tray3 and the HCI (if installed). LEGAL The HCIsize setting only indicates letter or A4 as these are the only LEDGER sizes supported by the HCI. Tray1size EXECUTIVE Tray2size A4 Tray3size A5 *HCIsize A3 JISB4 JISB5

CUSTOM

Control Panel 2-27, Test Menu Settings

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. Ready - - free 600dpi JUN 18 05:32.23 Message field

PCL LTR LTR

Ofnflliinee Printer is offline LTR Offline Custom Menu Test PapSize Figure 2-25 Test Function Button Test SETUPS

MAINT FONTS TABLE MENUS

Online TESTPRINT Online Select Figure 2-26 Test selections 2-28 Control Panel,

Test Menu Settings Control Panel Report Name Report Contents

• 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.

SETUPS • Maintenance Menu lists printer alignment characteristics that affect images. Report • 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. • 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.

MAINT 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.

Control Panel 2-29

,

Printer Tasks 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 Printer Tasks 3-1, Removing and Installing the Paper Trays

Removing and Installing the Paper Trays

1. Pull out the standard tray as shown in Figure 3-1. Tray

LTR

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.

LTR LTR

Figure 3-2 Pulling out Custom Tray 3-2 Printer Tasks, Adjusting Standard Tray Paper Guides

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.

LTR LTR

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 Printer Tasks 3-3,

Adjusting Standard Tray Paper Guides

7.16 8.26 10.11 11.69 5.84 7.25 8.5 11 (149 x 210mm) A5 8.26 (182 x 257mm) JISB5 10.11 (184 x 267mm) — 7.25 x 10.5 in. Executive 10.5 (216 x 280mm) — 8.5 x 11 in. Letter (210 x 297mm) A4 11.7 (216 x 356mm) — 8.5 x 14 in. Legal (257 x 364mm) JISB4 14.32 (297 x 420mm) A3 16.53 280 x 432mm) — 11 x 17 in. Ledger ("B" size)

Figure 3-4 Paper Sizes quick reference

3-4 Printer Tasks, Adjusting Standard Tray Paper Guides

Printer Tasks

1. Each paper guide has a blue locking thumbwheel, as shown in Figure 3-5. Guides (3) Locking devices

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Figure 3-5 Paper guides 2. Turn the blue locking thumbwheels on each paper guide counterclockwise to the OPEN position (Figure 3-6).

LTR LGR LTR

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.

OPEN LOSEC

Printer Tasks 3-5, Adjusting Standard Tray Paper Guides LOSC E

LTR LGR LTR

B4

LGL

B5 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).

LTR LGR LTR

Figure 3-8 Securing the paper guide

OPEN OSE CL OPEN

3-6 Printer Tasks, Setting Standard Paper Sizes

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. PapSize tray1size =LETTER tray2size =LETTER tray3size =LETTER

Online

Online 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). Contination arrows tray1size = LETTER

LEGAL LEDGER EXECUTIVE

A4 Online A5 Online Select Figure 3-10 Paper Size Selection Printer Tasks 3-7, Adjusting Custom Tray Paper Guides 5. Use M or N to move to the correct paper size (Figure 3-11). tray1size A3 JISB4 JISB5

CUSTOM

Online Select Figure 3-11 Paper size selection continuation 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. 3-8 Printer Tasks, Adjusting Custom Tray Paper Guides

Printer Tasks

1. Adjust the guides to the size of your paper. Figure 3-12 shows the adjustment guide travel directions. Thumbscrews to adjust left guide (finger tighten) Squeeze lever to release front and rear guides 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. Printer Tasks 3-9, Setting Custom Paper Sizes

Setting Custom Paper Sizes

The custom paper tray can accommodate a wide range of paper sizes, using continuously adjustable paper guides. The custom paper tray can accommodate paper stock as small as 4.75 x 7.2 inches (120 x 182 mm) or as large as 11.7 x 17 inches (297 x 431.8 mm). You can install one or more custom trays in the printer, but they must all be set to the same size. There are two tasks in setting up custom paper sizes in the custom tray: • Define the custom tray. • Set the paper size in the printer menu settings. (Save the dimensions and menu numbers in case you must refill the tray at some other time.) 1. To specify a tray as the custom tray, press PapSize on the Main Screen (Figure 3-13) to display the screen shown in Figure 3-14. This display identifies the paper size in each tray. Ready - - free 600dpi JUN 18 05:32.23 Message field

PCL LTR LTR

Ofnflliinee Printer is offline LTR Offline Custom Menu Test PapSize Figure 3-13 Main Screen 2. Press M or N to highlight the tray to define as a CUSTOM tray. PapSize tray1size =LETTER tray2size =LETTER tray3size =LETTER

Online

Online Figure 3-14 Paper tray selections 3-10 Printer Tasks, Configuring Custom Tray Menu Settings

Printer Tasks

3. Press P to get a list of paper sizes for this tray, as shown in Figure 3-15. Contination arrows tray1size = LETTER

LEGAL LEDGER EXECUTIVE

A4 Online A5 Online Select 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). tray1size A3 JISB4 JISB5

CUSTOM

Online Online Select 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, usinga5x8inch 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. Printer Tasks 3-11, Configuring Custom Tray Menu Settings 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, 100x8= 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. Menu Printing Configuration

PCL

Comms Maintenance

Online

Online 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). Configuration newline = CR+LF traylock sizes = CONFIRM imageshift customsize

Online units = 1/720"

Online Figure 3-18 Configuration options 3-12 Printer Tasks, Configuring Custom Tray Menu Settings

Printer Tasks

10. Press M or N to select your unit size selections (Figure 3-19). Configuration.units 1/100" 1/200" 1/300" 1/600" = 1/720"

Online MM

Online Select Figure 3-19 Unit size selections 11. In our example, 1/100" is highlighted (Figure 3-20). Configuration.units 1/100" 1/200" 1/300" 1/600" 1/720"

Online MM

Online Select Figure 3-20 Highlighting 1/100" 12. Press Select. Figure 3-20 is displayed. 13. Press M to highlight customsize (Figure 3-21). Configuration newline = CR+LF traylock sizes = CONFIRM imageshift customsize

Online units = 1/100"

Online Figure 3-21 Customsize selection Printer Tasks 3-13, Configuring Custom Tray Menu Settings 14. Press P to highlight width. Configuration.customsize width = 8416 height = 12240

Online

Online Figure 3-22 Customsize width and height selections 15. Press M or N until your number is highlighted (our example is 500, as shown in Figure 3-23). Configuration.customsize width = 500

Online 505

Online Select Figure 3-23 Width selection for custom paper size 16. Press Select. 17. Press N to highlight height. 3-14 Printer Tasks, Configuring Custom Tray Menu Settings

Printer Tasks

18. Press M or N until your number is highlighted (our example is 800, as shown in Figure 3-24). Configuration.customsize height = 800

Online 805

Save Select Figure 3-24 Height selection for Custom Paper Tray 19. Press Select. 20. Press Save. Printer Tasks 3-15, Loading Paper Into Trays and HCI

Loading Paper Into Trays and HCI

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

Opening Paper

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 3-16 Printer Tasks, Loading Paper Into Trays and HCI

Printer Tasks

Table 3-2 Paper orientation in trays and HCI Input Tray

HCI

Short edge leading Long edge leading Single-sided TOF TOF printing to output tray or Double-sided printing to HCO Face down Face down Face up

TOF

Double-sided printing to TOF TOF output tray TOF = Top Of Face up Face up Face down Form

TOF

Tip Use the arrow on the paper package as a guideline for loading paper. For the HCI, load paper so that the arrow on the package is pointing upward. For trays, load paper so that the arrow on the package is pointing downward. Printer Tasks 3-17, Locking Paper Trays

Locking Paper Trays

All paper sources with the same size of media are automatically linked together. This means that the printer will automatically switch to the next tray when the current tray runs out of paper. This could cause problems when all of the paper trays are set to the same size of paper, but contain different types of paper, such as plain paper and letterhead. In order to eliminate the linking of trays, you must "lock" the trays you don’t want selected unless the job gives a direct command to use paper from that source. For example, if you have a tray with letterhead paper in it, you may want to lock out this tray so that if the other trays run out of paper, the letterhead paper tray would not be used. The printer does not detect the paper size loaded in a particular tray. Follow this procedure to lock a paper tray: 1. On the Main Screen, press Menu. 2. Press N to move to Configuration (Figure 3-26). Menu Printing Configuration

PCL

Comms Maintenance

Online

Online Figure 3-26 Configuration Menu 3. Press P to select Configuration. 3-18 Printer Tasks, Locking Paper Trays

Printer Tasks

4. Press N to move to traylock (Figure 3-26). Configuration = newline = CR + LF traylock sizes = CONFIRM imageshift customsize units = 1/720" Online Online 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). Configuration.traylock tray1 =UNLOCKED tray2 =UNLOCKED tray3 =UNLOCKED

Online

Online Figure 3-28 Configuration.traylock Printer Tasks 3-19, Locking Paper Trays 7. For example, if you want to lock tray1, press P to select tray1. (See the screen in Figure 3-29.) Configuration.traylock.tray1 = tray1 = UNLOCKED

LOCKED

Online Online Select Figure 3-29 Configuration.traylock.tray1 8. Press N to move to locked. 9. Press Select. You return to the Configuration.traylock screen with tray1 locked (Figure 3-30). Configuration.traylock tray1= LOCKED tray2 = UNLOCKED tray3 = UNLOCKED

Online

Save Figure 3-30 Tray 1 locked 10. Press Save to save the changes in PwrOnConfig. 3-20 Printer Tasks, Stopping or Interrupting Print Jobs

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. Ready - - printing 600dpi JUN 18 05:32.23

PCL

Cen LTR

LTR

Onffline LTR Offline Menu End 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. End = PAUSE

ENDDOC SUPPRESS ABANDON

Online Online Select Figure 3-32 End Submenu Printer Tasks 3-21, Clearing a Paper Jam The choices available are: PAUSE Temporarily stops the job. Use this to pause the printer, such as when adding or removing paper or adding toner. Any incomplete or partial pages are printed (like a form feed or page eject). The job ENDDOC 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. 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 SUPPRESS 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. Ends processing of the current job and clears all data in the input buffer. This is the ABANDON most direct, quickest, and potentially risky way of stopping a current job. Use ABANDON only when you are certain that the data in the print job is not required by future print jobs.

Clearing a Paper Jam

When you start a print job, the printer selects paper, a page at a time, from one of the internal trays or from the external HCI. Paper jams may occur if the paper is wrinkled, folded, skewed, or out of specification. The printer goes Offline until the paper jam is cleared. When a jam occurs, refer to the Control Panel for a visual and written description of the jam location. For a visual indication refer to the picture on the right side of the Control Panel. The area in the paper path where the jam occurred will be blinking. More than one sheet of paper may be located in the paper path; all sheets must be removed before the printer will resume printing. In this case, the paper path diagram may continue blinking in the same or another location, and the printer displays messages about the location of remaining sheets until all jams are cleared. Note The printer is forced Offline until the problem is fixed. Table 3-3 lists each paper jam that displays on the Control Panel and how to clear the jam. More detailed information on clearing paper jams appears on the pages listed. You can also refer to the illustrated jam clearing pictures located on the inside of the printer’s front door. 3-22 Printer Tasks,

Clearing a Paper Jam Printer Tasks Table 3-3 Paper jams and remedies Refer to Paper Jam Messages Remedy

page Paper Input Jams

TRAY1 Pick error Remove tray (1, 2, or 3), remove paper jam from paper entry 3-24 TRAY2 Pick error area and/or within tray. TRAY3 Pick error Feed jam 1 Open the front door, lower transfer assembly, rotate knob 1 3-26

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

Feed jam 2 Open the side door, remove jammed paper. 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 3-26

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

Fuser unit jam 1 Open the front door, lower transfer assembly, open lever 4, 3-36 Fuser unit jam 2 push decurler lever down, remove jammed paper to the

right.

Duplex path jam 1 Open the front door, raise lever 6, and remove jammed 3-38 Duplex path jam 2 paper. You may need to turn duplex roller knob to release

the paper.

Print unit path jam (Reversing unit area jam) 3-40

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

Ejection unit jam 1 Raise the paper ejection cover and remove jammed paper. 3-43 Ejection unit jam 2 HCO jam 1 Open the HCO door, rotate roller knob 1 to free paper, then 3-45 HCO jam 2 lift levers to remove paper. Printer Tasks 3-23

, Clearing Paper Input Jams

Clearing Paper Input Jams Clearing a Tray Pick Error Jam

When the printer tries to load a sheet of paper from one the paper trays and encounters a picking problem, the Control Panel shows a blinking section at the output of the problem tray as shown in Figure 3-33. **** Pick error 600dpi Remove paper & Press Clear PCL Blinking

LTR LTR

Offliine LTR Clear Menu End **** TRAY1 TRAY2 TRAY3 Figure 3-33 Pick error jam indication To clear the tray pick error: 1. Open the indicated paper tray, as shown in Figure 3-34.

LTR LTR LTR

Figure 3-34 Opening paper tray 3-24 Printer Tasks, Clearing Paper Input Jams

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. Lower right cover

LTR LTR LTR

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. Printer Tasks 3-25, Clearing Paper Input Jams

Clearing a Feed Path Paper Jam

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

LTR LTR

Offline LTR Clear Menu Test PapSize *****: Feed path jam 1 Feed path jam 2 Feed path jam 4 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. 3-26 Printer Tasks, Clearing Paper Input Jams

Printer Tasks

Paper

LTR LTR LTR

Lower right door Figure 3-37 Removing paper from side door opening

LTR LTR LTR

Figure 3-38 Unlatching the HCI Printer Tasks 3-27, Clearing Paper Input Jams 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. Handle 3 Figure 3-39 Lowering Transfer Assembly 3-28 Printer Tasks, Clearing Paper Input Jams

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. Printer Tasks 3-29, Clearing Paper Input Jams Knob 2 Knob 1 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. 3-30 Printer Tasks, Clearing Paper Input Jams

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. Printer Tasks 3-31, Clearing Paper Input Jams

Clearing HCI Jams

When the printer tries to obtain a sheet of paper from the HCI and the paper fails to load properly, this is an HCI paper jam. This is indicated on the Control Panel by the blinking paper path shown in Figure 3-43. • HCI jam 1(pick error), a jam where the paper did not leave the HCI correctly. • HCI jam 2 (jam), a jam where the paper did not enter the printer correctly. • HCI jam 3 (jam), a jam where the paper is between the printer and the HCI. HCI jam 2 600dpi Remove paper & Press Clear PCL Blinking Cen LTR LTR LTR Offliine LTR Offline Menu End 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.

LTR LTR LTR

Figure 3-44 Opening the HCI door 3-32 Printer Tasks, Clearing Paper Input Jams

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.

LTR LTR LTR

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.

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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. Printer Tasks 3-33, Clearing Paper Input Jams

Clearing HCI Jam 2

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

LTR LTR LTR

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:

LTR LTR LTR

Figure 3-48 Removing paper between the HCI and the printer 3-34 Printer Tasks, Clearing Paper Path Jams

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. 600 dpi Remove paper & Press Clear PCL Blinking

LTR LTR

*OOffflliine* LTR Clear Menu Test PapSize *****: Fuser unit jam Duplex path jam Print unit path jam Figure 3-49 Paper path jams indication Printer Tasks 3-35, Clearing Paper Path Jams

Clearing a Fuser Unit Jam

The fuser unit jam is located after the drum. 1. Open the front door and lower the Transfer Assembly, as shown in Figure 3-50. Lever 4 Figure 3-50 Lowering Transfer Assembly 2. 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. 3-36 Printer Tasks, Clearing Paper Path Jams

Printer Tasks

Thumb on decurler lever 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. Printer Tasks 3-37, Clearing Paper Path Jams

Clearing a Duplex Unit Jam

The duplex unit jam is indicated on the Control Panel as shown in Figure 3-53. Blinking Duplex path jam 2 600dpi Remove paper & Press Clear

PCL LTR LTR

Offline LTR Clear Menu End 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. Duplex roller knob Lever 6 Figure 3-54 Freeing Duplex Jam 3-38 Printer Tasks, Clearing Paper Path Jams

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. Printer Tasks 3-39, Clearing Paper Path Jams

Clearing a Reversing Unit Area Jam

The reversing unit area paper path jam is located to the left of the duplex unit. 1. Open the front door and turn Lever 4 fully clockwise, shown in Figure 3-56. This removes pressure on paper leaving the fuser unit area. Lever 4 Figure 3-56 Opening Lever 4 2. Locate Lever 5 and push it downward and away from the fuser unit area, as shown in Figure 3-57. 3-40 Printer Tasks, Clearing Paper Path Jams

Printer Tasks

Decurler roller knob Lever 5 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 Printer Tasks 3-41, Clearing Paper Path Jams 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. 3-42 Printer Tasks, Clearing Paper Output Jams

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. Ejection unit jam 2 600dpi Blinking Remove paper & Press Clear

PCL LTR LTR

Offliine LTR Clear Menu End 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 Printer Tasks 3-43, Clearing Paper Output Jams 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. 3-44 Printer Tasks, Clearing Paper Output Jams

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. Blinking HCO jam 1 600dpi

PCL

Cen LTR

LTR

Offliine LTR Offline Menu End 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 Printer Tasks 3-45, Clearing Paper Output Jams 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. HCO Knob 1 Figure 3-65 HCO Knob 1 Paper Input Roller 3. Pull lever 2 back (Figure 3-66) and remove any paper.

HCO

Lever 2 Figure 3-66 Clearing HCO lower section paper jam using Lever 2 3-46 Printer Tasks, Clearing Paper Output Jams

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. HCO Lever 1 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. Printer Tasks 3-47, Clearing Paper Output Jams Separating the HCO and Printer To separate the HCO from the printer: 1. The printer physically connects to the HCO with a connecting pin, which fits into the corresponding positioning hole on the HCO. See Figure 3-68. Connecting Pin Positioning Hole Bracket B Bracket A Figure 3-68 Separating HCO and printer 2. Figure 3-69 shows detailed look at the connecting pin and the positioning hole. Printer Push HCO Printer HCO left to disengage Pin Pin Unscrew Bracket A Pull HCO away from printer Figure 3-69 Printer connecting pin and HCO positioning hole configuration 3-48 Printer Tasks, Handling Error Messages and Troubleshooting

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. Front door open Error message 600dpi Close front door Action message PCL 12.145 Cen LTR

LTR

Onfflliinnee LTR Clear Custom Menu Test PapSize Figure 3-70 Error reporting Printer Tasks 3-49, Handling Error Messages and Troubleshooting

Error Reporting/Action Response

Refer to “Error Messages” on page A-7, for how to interpret error messages. In the unlikely event that the printer has a major error, follow these steps: 1. 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. Blinking Error code High-voltage power supply alarm Call Engineer (SVC 6F)

PCL LTR LTR

Offliine LTR Clear Menu End Figure 3-71 Call Engineer (Service Representative) 3-50 Printer Tasks, nsumables

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 and Replacing Consumables 4-1

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, Ordering D640 Printer Consumables

Ordering D640 Printer Consumables

You can order consumables directly from Hewlett-Packard by calling 1-800-538-8787 in the United States and Canada. Customers outside the United States and Canada should contact their local Hewlett-Packard sales office. Please plan for a two to five day delivery in the United States, possibly longer outside the United States. If your printer was purchased from a Hewlett-Packard reseller, you may be able to purchase consumables directly from them. Table 4-1 lists the D640 printer consumables, ordering numbers, kit content descriptions and quantities, along with the length of time you can expect them to last under optimum operating conditions. Use the replacement cycle estimates in Table 4-1 to plan your initial consumable purchases. Because yields may vary widely from the estimates, you should track your actual usage to establish proper replacement schedules for each printer installation. Actual yields depend upon: • Media (paper type, weight, chemical composition, perforations, paper dust, and quality). • Media storage factors such as care and handling, room temperature, and humidity. • Exposure to light (photoconductor drum). • Frequency of cleaning the printer. • Average print job size, daily print volume, and patterns of printing. • Ambient environmental conditions, such as temperature, humidity, and static electricity. • Power-on hours. “Managing Consumables” on page 6-6 describes some of the considerations in using and replacing consumables. 4-2 Ordering and Replacing Consumables, Ordering D640 Printer Consumables nsumables Table 4-1 Consumables, product part numbers, and replacement cycles Product Replacement Cycle Shelf Item Contents Qty Number (Estimated) Life Toner Kit C5626A Toner bottles 8 each Up to 180,000 page sides 18 months Collector bottles 8 each Note: Yield based on 4% Cleaning rollers 4 each toner coverage Developer Kit C5632A Developer bottles 2 each Up to 250,000 page sides 18 months Ozone filter 1 each Drum Kit C5629A Photoconductor 1 each Up to 195,000 page sides 18 months drum 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 C5633A Printer pick rollers 1 set Up to 500,000 pages Inf. Roller Kit HCI Pick C5636A HCI pick rollers 1 set Up to 500,000 pages Roller Kit Note: Replacement cycles based on letter or A4 sized media. Larger sized media require more frequent replacement. Note A new printer will report toner low and need to be refilled the first time after printing about 6,000 images. This is normal and is due to the toner hopper being completely empty in a new printer. The estimated yields listed are not a warranty or guarantee of minimum life and are provided to assist in initial supplies planning. Yields may vary widely based on applications and operating conditions. Yield estimate are based on, but not limited to, ideal environmental and operating conditions, print jobs averaging 4% toner coverage per page, and an average job of 25 pages. Ordering and Replacing Consumables 4-3

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, Replacing Toner

Replacing Toner

The toner comes in a kit that contains bottles of toner, empty toner collector bottles, and fuser cleaning rollers. The toner collector bottle is replaced with every bottle of toner. The fuser cleaning roller is replaced after every two bottles of toner. Note Replace the cleaning roller every other toner replacement. Caution Only add toner when the printer displays a toner low or toner empty message. Never try to add toner before the printer requires it. Never add more than one bottle of toner. Overfilling causes toner spills. When the toner starts to get low, the Control Panel displays: Toner Low Add New Toner A Toner Low condition does not stop the printer. Toner can be added between jobs or during a job by pressing Offline: 1. Press Offline. 2. Open the upper right cover (Figure 4-1) to access the toner hopper and toner collector bottle. ... ... Toner collector bottle Toner hopper Upper right cover open Figure 4-1 Opening Upper Right Cover 4-4 Ordering and Replacing Consumables, Replacing Toner nsumables 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. Toner fill flap 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. Ordering and Replacing Consumables 4-5

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, Replacing Toner Empty toner bottle Toner bottle Handle Guide pin Figure 4-3 Filling the toner and removing the Toner Bottle Note It will take about 30 seconds for the toner to empty into the toner hopper. Because the toner bottle is translucent, you should be able to see the toner empty out of the bottle. 8. 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. Toner fill flap Figure 4-4 Closing the Toner Fill Flap 10. Discard the toner bottle. The toner bottle is made of recyclable materials. Dispose of it according to local regulations. 4-6 Ordering and Replacing Consumables, Replacing Toner nsumables

Replacing the Toner Collector Bottle

If you have toner recycling turned on, you can skip this step. For information about toner recycling, refer to “Managing Consumables” on page 6-6. When you replace the toner, remove the old toner collector bottle and replace it with a new, empty one. Refer to Figure 4-5 for an illustration of the toner collector bottle location. Pull out old bottle Insert new bottle Figure 4-5 Toner Collector Bottle Replacement Dispose of the old toner collector bottle in accordance with local regulations. Close the upper right cover.

Replacing the Cleaning Roller (When Indicated on Control Panel)

WARNING! Handle the old cleaning roller carefully, as it may be hot. Replace the cleaning roller during every other toner replacement, as directed on the Control Panel. 1. Open the front door. 2. Pull out the old cleaning roller, as shown in Figure 4-6. Ordering and Replacing Consumables 4-7

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, Replacing Toner Cleaning roller

LTR

Figure 4-6 Removing the Cleaning Roller 3. Insert the new cleaning roller until it clicks into place, as shown in Figure 4-7. Cleaning roller

LTR

Figure 4-7 Inserting the Cleaning Roller 4-8 Ordering and Replacing Consumables, Replacing Developer nsumables 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. Menu Printing Configuration

PCL

Comms Maintenance

Online

Online Figure 4-8 Menu Ordering and Replacing Consumables 4-9

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, Replacing Developer 2. Use N to highlight Maintenance, as shown in Figure 4-9. Menu Printing Configuration

PCL

Comms Maintenance

Online

Online Figure 4-9 Maintenance 3. Use P to display Maintenance selections as shown in Figure 4-10. Maintenance replace alignment density = 10 testpages = 30 monitor = OFF

Online date-time

Online Figure 4-10 Maintenance selections 4. Use P to display replace selections, as shown in Figure 4-11. Developer is shown selected. Maintenance.replace DEVELOPER DRUM UNIT FUSER UNIT TRAY1ROLLERS TRAY2ROLLERS

Online TRAY3ROLLERS

Online Select Figure 4-11 Replace selections 4-10 Ordering and Replacing Consumables, Replacing Developer nsumables 5. Press Select to display Developer instructions, as shown in Figure 4-12. Developer Replacement Prepare new developer and press Start to discharge old developer LTR

LTR LTR

Start Exit 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. Blinking Developer discharge Developer discharging Please Wait

Online

Figure 4-13 Developer discharging Ordering and Replacing Consumables 4-11

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, Replacing Developer 8. After 45 seconds, you see the display shown in Figure 4-14. Blinking Developer discharge completed Prepare new developer bottle Open upper right cover Press Done

Online

Done Figure 4-14 Developer discharge complete 9. Press Done.

Adding New Developer

1. Open the upper right cover and locate the developer bottle as shown in Figure 4-15. ........ Developer collector bottle Upper right cover Figure 4-15 Developer and Developer Collector Bottle 4-12 Ordering and Replacing Consumables, Replacing Developer nsumables 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. Ordering and Replacing Consumables 4-13

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, Replacing Developer 7. Open the developer fill flap, as shown in Figure 4-17. Developer fill flap 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. Developer bottle Developer bottle Guide pin Guide pin slot Figure 4-18 Filling the Developer and tapping the Developer Bottle 4-14 Ordering and Replacing Consumables, Replacing Developer nsumables 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. Empty developer bottle Figure 4-19 Removing the Developer Bottle and closing the Fill Flap 11. Close the developer fill flap, as shown in Figure 4-19. 12. Press Done. The Control Panel displays: Developer injection complete Remove and Cap Old Bottle Install Empty New Bottle Close Cover and Press Done Ordering and Replacing Consumables 4-15

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, Replacing Developer

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. Empty bottle 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. 4-16 Ordering and Replacing Consumables, Replacing Developer nsumables

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. Handle Handle Ozone filter holder Ozone filter 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. Ordering and Replacing Consumables 4-17

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, Drum Kit - Replacing Drum and Transfer Assembly

Drum Kit - Replacing Drum and Transfer Assembly

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

Setting Up the Printer for Drum Kit Replacement

1. 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. Drum Replacement Replace Drum unit and Press Done

Online

Done Figure 4-22 Replace Drum 4-18 Ordering and Replacing Consumables, Drum Kit - Replacing Drum and Transfer Assembly nsumables

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. Handle 3

LTR

Transfer assembly guide Figure 4-23 Handle 3 and Transfer Assembly Guide Ordering and Replacing Consumables 4-19

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, Drum Kit - Replacing Drum and Transfer Assembly 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. Transfer assembly guide Transfer assembly Transfer assembly guide Pin Transfer assembly Wire LTR Figure 4-24 Removing the Transfer Assembly 4. Discard the transfer unit. 4-20 Ordering and Replacing Consumables, Drum Kit - Replacing Drum and Transfer Assembly nsumables

Removing the Drum

1. Turn drum locking knob counterclockwise two or three turns to unlock the drum, as shown in Figure 4-25. Twist thumbscrew Lever b1 Handle 3

LTR

Figure 4-25 Releasing the Drum Ordering and Replacing Consumables 4-21

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, Drum Kit - Replacing Drum and Transfer Assembly 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. Guide rails Top handle Lever b1 Front handle 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. 4-22 Ordering and Replacing Consumables, Drum Kit - Replacing Drum and Transfer Assembly nsumables

Unpacking the New Drum

1. Open the vacuum sealed bag containing the drum and remove it, as shown in Figure 4-27. Drum Figure 4-27 Unpacking Drum and removing the Protective Cover 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. Ordering and Replacing Consumables 4-23

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, Drum Kit - Replacing Drum and Transfer Assembly

Installing the Drum

1. Make sure Lever b1 is in the OPEN position. Use the drum handles on the top and front to insert the drum along the guide rails until it stops, as shown in Figure 4-28. Push forward gently until the drum meets the positioning pins. Top handle Guide rails Drum alignment pins Front handle Lever b1 Alignment pin holes Figure 4-28 Inserting the Drum 4-24 Ordering and Replacing Consumables, Drum Kit - Replacing Drum and Transfer Assembly nsumables 2. Gently push the drum onto the positioning pins (Figure 4-29). (2) Drum Alignment Pins 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. Ordering and Replacing Consumables 4-25

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, Drum Kit - Replacing Drum and Transfer Assembly 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. Drum locking knob

LTR

Figure 4-30 Securing the Drum 4. Rotate Lever b1 counterclockwise to lock the drum in place. 4-26 Ordering and Replacing Consumables, Drum Kit - Replacing Drum and Transfer Assembly nsumables

Installing the New Transfer Assembly

1. Remove the transfer assembly from its packaging. Caution As you handle the transfer assembly, take care not to touch or damage the transfer wire. 2. Using the alignment pin located on the end of the transfer assembly, insert the alignment pin of the transfer assembly into the left rail of the transfer assembly guide and push in to the end of the guide as shown in Figure 4-31. Transfer assembly guide Transfer assembly Transfer assembly guide Pin Transfer assembly Wire LTR Figure 4-31 Inserting the Transfer Assembly into the Guide Ordering and Replacing Consumables 4-27

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, Drum Kit - Replacing Drum and Transfer Assembly 3. Secure the transfer assembly guide by lifting Handle 3 until it snaps into place as shown in Figure 4-32. Handle 3 Transfer assembly guide LTR Figure 4-32 Securing the Transfer Assembly 4. Close the front door. 5. Use the drum kit packing materials to repack for disposal. 4-28 Ordering and Replacing Consumables, Fuser Kit - Replacing the Fuser nsumables

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. Fuser unit Replacement Replace Fuser unit and Press Done

Online

Done Figure 4-33 Fuser instructions Ordering and Replacing Consumables 4-29

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, Fuser Kit - Replacing the Fuser

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. Fuser locking knob

LTR

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. Fuser

LTR

Figure 4-35 Pulling the Fuser out 4-30 Ordering and Replacing Consumables, Fuser Kit - Replacing the Fuser nsumables

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. Fuser Figure 4-36 Installing the Fuser Ordering and Replacing Consumables 4-31

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, Fuser Kit - Replacing the Fuser 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. Decurler roller knob 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. 4-32 Ordering and Replacing Consumables, Printer Pick Roller Kit - Replacing the Tray Pick Rollers nsumables

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. Pick rollers Tray1 Pick rollers Tray2 Pick rollers Tray3 Figure 4-38 Removing Paper Trays - all trays removed Ordering and Replacing Consumables 4-33

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, Printer Pick Roller Kit - Replacing the Tray Pick Rollers 2. Locate the thumb screw holding the steel plate over the lower tray roller assembly, as shown in Figure 4-39. Thumbscrew Figure 4-39 Locating Thumbscrew 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 4-34 Ordering and Replacing Consumables, Printer Pick Roller Kit - Replacing the Tray Pick Rollers nsumables 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 Ordering and Replacing Consumables 4-35

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, Printer Pick Roller Kit - Replacing the Tray Pick Rollers 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 4-36 Ordering and Replacing Consumables, Printer Pick Roller Kit - Replacing the Tray Pick Rollers

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 Ordering and Replacing Consumables 4-37, Printer Pick Roller Kit - Replacing the Tray Pick Rollers 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. Notch correctly positioned to go Roller correctly installed all the way, over metal peg with notch over the metal peg 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. Larger lower roller positioned on the Larger lower roller rotated to same shaft as the smaller roller engage plastic pegs on smaller Figure 4-48 Correct Larger Lower Roller placement 4-38 Ordering and Replacing Consumables, Printer Pick Roller Kit - Replacing the Tray Pick Rollers nsumables 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. Blue clip placed on lower Blue clip snapped into place on roller shaft lower roller shaft groove Figure 4-49 Blue Clip snapped into place

Installing the Printer Upper Pick Rollers

When you install the printer’s upper pick rollers, the slot on the pick roller assembly must mate with the corresponding mounting tooth on the printer bracket. See Figure 4-50. Metal tooth Slot Figure 4-50 Upper Pick Roller Assembly Slot and Mounting Tooth on printer Ordering and Replacing Consumables 4-39

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, Printer Pick Roller Kit - Replacing the Tray Pick Rollers 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 4-40 Ordering and Replacing Consumables, Printer Pick Roller Kit - Replacing the Tray Pick Rollers nsumables

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. Ordering and Replacing Consumables 4-41

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, HCI Pick Roller Kit - Replacing the HCI Pick Rollers

HCI Pick Roller Kit - Replacing the HCI Pick Rollers

This section provides the procedures to remove and replace the HCI pick rollers. When the HCI pick rollers need to be replaced the Control Panel indicates: HCI Pick Roller At End of Life Replace HCI Pick Roller or when you get excessive feed errors from the HCI. Note We recommend that you use a small flashlight to help you see the inside of the HCI while working in it.

At the Control Panel

1. 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.

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Figure 4-55 Sliding HCI away from printer 4-42 Ordering and Replacing Consumables, HCI Pick Roller Kit - Replacing the HCI Pick Rollers nsumables 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.

LTR LTR LTR

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 Ordering and Replacing Consumables 4-43

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, HCI Pick Roller Kit - Replacing the HCI Pick Rollers 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 4-44 Ordering and Replacing Consumables, HCI Pick Roller Kit - Replacing the HCI Pick Rollers nsumables 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 Ordering and Replacing Consumables 4-45

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, HCI Pick Roller Kit - Replacing the HCI Pick Rollers 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 4-46 Ordering and Replacing Consumables, HCI Pick Roller Kit - Replacing the HCI Pick Rollers nsumables 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 Ordering and Replacing Consumables 4-47

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, HCI Pick Roller Kit - Replacing the HCI Pick Rollers 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 4-48 Ordering and Replacing Consumables, HCI Pick Roller Kit - Replacing the HCI Pick Rollers nsumables

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 Ordering and Replacing Consumables 4-49

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, HCI Pick Roller Kit - Replacing the HCI Pick Rollers 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.

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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. 4-50 Ordering and Replacing Consumables,

Maintenance Maintenance Introduction

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

Weekly Cleaning

Investing just a few minutes on your D640’s maintenance each week ensures minimum downtime and maintains high print quality. Make sure someone is responsible for printer maintenance. Perform the maintenance tasks at the recommended intervals. Use these tools for cleaning: • Cleaning cloths (supplied with the D640 printer) • Rags • Vacuum cleaner specially designed for picking up toner • Blower brush (supplied with the D640 printer) Note Turn the main power switch OFF before performing the weekly cleaning. Caution Make sure that the toner vacuum is properly grounded before using it in the printer, or the printer may sustain electrical damage. Refer to the vacuum’s operating manual. Maintenance 5-1, Weekly Cleaning

Removing Stray Toner

During removal or replacement of various consumable parts, toner occasionally spills onto the printer interior or exterior. • Do not attempt to clean up spilled toner with water or any other fluid, as this can harm the developer, toner, and printer mechanism. • Use a vacuum cleaner especially designed for trapping toner particles. Regular vacuum cleaners cannot trap the fine toner particles and will exhaust them back into the air. If you are unsure which vacuum cleaner to use, consult your service representative. Toner Hopper Area To clean the toner hopper area, follow these steps: 1. 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. 5-2 Maintenance, Weekly Cleaning

Maintenance Precharger Area

The precharger is a wire located inside the drum. The drum contains a built-in cleaning rod to remove toner that might build up on the precharger wire. To clean the precharger, follow these steps: 1. Pull out the precharger cleaner handle (Figure 5-2), then push it back into its original location. Repeat this "out-in" process 4 or 5 times. Precharger cleaner Figure 5-2 Cleaning the Precharger 2. Push the precharger cleaner in completely. Maintenance 5-3, Weekly Cleaning

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. 5-4 Maintenance, Periodic Cleaning (When Replacing Drum)

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 Maintenance 5-5, Periodic Cleaning (When Replacing Drum)

Duplex Area

Caution As you clean the duplex unit, avoid wiping the paper sensor from right to left or perpendicular to the paper feeding direction. Wipe the area from left to right. 1. Raise lever 6 and use the supplied cleaning cloths to wipe up any toner or dust off the duplex area in this area, wiping from left to right. Wipe all of the accessible area to ensure a thorough cleaning. See Figure 5-5. Figure 5-5 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. 5-6 Maintenance, Periodic Cleaning (When Replacing Drum)

Maintenance

Handle 3 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. Transfer assembly guide Transfer assembly Transfer assembly guide Pin Transfer assembly Wire LTR Figure 5-7 Removing the Transfer Assembly Maintenance 5-7, Periodic Cleaning (When Replacing Drum) 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 5-8 Maintenance, Periodic Cleaning (When Replacing Drum)

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 Maintenance 5-9, Periodic Cleaning (When Replacing Drum)

LED Array Area

To clean the LED Array: 1. Use the supplied cleaning cloths to wipe up any toner or dust off the outside of the LED array. Clean all the way across the LED array. Figure 5-10 shows the LED array and illustrates the cleaning procedure. Caution Be careful to avoid contacting the developer unit roller on the right side of the area, as this could damage the developer. Figure 5-10 Cleaning LED Array 2. Install the new drum assembly, as described in “Drum Kit - Replacing Drum and Transfer Assembly” on page 4-18. 5-10 Maintenance, Periodic Cleaning (When Replacing Drum)

Maintenance Reinstalling the Transfer Assembly

1. Using the alignment pin located on the end of the cleaned transfer assembly, insert the alignment pin of the transfer assembly into the left rail of the transfer assembly guide and push in to the end of the guide. See Figure 5-11. Transfer assembly guide Transfer assembly Transfer assembly guide Pin Transfer assembly Wire LTR Figure 5-11 Inserting the Transfer Assembly into the guide Maintenance 5-11, Periodic Cleaning (When Replacing Drum) 2. Secure the transfer assembly by lifting Handle 3, as shown in Figure 5-12. Handle 3 Transfer assembly guide LTR Figure 5-12 Securing the Transfer Assembly 3. Close the front door. Note If you have problems reinstalling the transfer assembly, check to see that the drum is installed correctly. 5-12 Maintenance,

Advanced Topics Advanced Topics

This chapter presents information about: • Maintaining print quality • Managing consumables • Adjusting paper path alignment • Setting up edge-to-edge printing • Configuring for LaserJet compatibility • Using virtual font cartridges The topics in this chapter help you find new uses for the printer, manage your consumable supplies, and maintain optimum print quality.

Maintaining Print Quality

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

Print Quality Troubleshooting

If you are dissatisfied with the quality of your prints: 1. 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. Advanced Topics 6-1, Maintaining Print Quality 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.) 6-2 Advanced Topics, Maintaining Print Quality

Advanced Topics Good Quality Print Sample

Figure 6-1 Good quality print sample Advanced Topics 6-3, Maintaining Print Quality

Specific Print Quality Problems

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

Fading

If a white streak or a faded area appears on the page (in the direction the paper passes through the printer): • Check the Economode setting; be sure it is OFF. (See “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. 6-4 Advanced Topics, Maintaining Print Quality

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. Advanced Topics 6-5, Managing Consumables

Repetitive Defects

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

Managing Consumables

Use the following checklist to identify actions you can take to maximize consumable yields. Further detailed information is provided later in this section. 1. 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. 6-6 Advanced Topics, Managing Consumables

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. Advanced Topics 6-7, Managing Consumables Recycling Printers that user powdered toner generally only transfer about 70 to 80% of the toner used for a page image to the paper. The remaining 20 to 30% is known as waste toner because in most printers it is thrown away. In a printer that uses a toner cartridge, the waste toner is never seen because it is moved to a waste area inside the print cartridge. The D640 printer is unique in the industry, providing the choice of recycling the waste toner or throwing it away. As the printer ships from the factory, the toner recycling mode is disabled and waste toner collects in a bottle. You remove and throw out this bottle each time you add a new bottle of toner. With toner recycling enabled, the waste toner is funneled back into the toner hopper and gradually mixed with new toner. The disadvantage to recycling toner is a possible slight reduction in print quality. Print may appear lighter and small voids may be visible in dark images. In most text applications, you will probably not notice any reduced print quality with recycling on. If your application requires the best possible print quality, do not use toner recycling. Unlike Density and Economode, the effects of toner recycling are not immediately noticeable when you stop recycling. The waste toner must be completely flushed from the toner path. Depending on how long the recycling feature was used, it might take up to five bottles of new toner before the waste toner is completely flushed from the system. Toner Recycling Switch Toner recycling is enabled or disabled by moving the plastic slide switch located directly over the toner collector bottle. When it is pushed to the right, toner is recycled. When it is pushed to the left, waste toner collects in the toner collector bottle for disposal. Figure 6-2 shows the bottle and switch location. 6-8 Advanced Topics, Managing Consumables

Advanced Topics

Toner Recycle Slide Figure 6-2 Toner Recycling Slide Switch

Drum and Developer

The drum and developer are grouped together because their yields depend on drum rotations. There is physical wear on the drum and developer mixture with every rotation of the drum. The drum is often rotating even when the printer is not printing. Factory yield estimates for the drum and developer, listed on the data sheet and in this manual, can never be accurate because there is not a one-to-one correspondence between drum rotations and printed pages. However, the internal counters in the printer do count drum rotations for both the drum and developer. The drum life is estimated at 250,000 drum rotations and the developer life is estimated at 160,000 drum rotations. The drum rotates during power up, at the start and end of each job, and while printing each image. Knowing what factors drive drum rotations helps you understand what determines the lives of your drum and developer. Frequent power cycling or lapses into power save mode add wear to the drum and developer. During power-up or coming out of power save mode, the drum rotates for up to two minutes. This can produce as many as 80 drum rotations even though no pages are printed. Advanced Topics 6-9, Managing Consumables The average number of pages in print jobs has a large effect on drum and developer life. Extra drum rotations occur at the start and end of each job. There are four rotations at the beginning and four rotations at the end. If the D640 primarily prints very small jobs (less than 25 pages), you get lower than rated yields on the drum and developer. If you primarily print jobs larger than 25 pages, you get higher than expected yields. There is also a negative effect on drum rotations if you print complex images that slow the printer down. If the printer controller cannot process the incoming data fast enough to keep the printer running at 40 pages per minute, extra drum rotations occur for the print job. The estimated yields for the drum and developer assume a job size of 25 page sides per job. It is not important if you occasionally print small jobs or complex images; it’s important how your print environment averages usage over a long period of time. The drum surface is easily damaged by scratches, long exposure to fluorescent light (30 minutes), or exposure to direct sunlight (which may cause gray background shading). The estimated yields do not account for replacement due to these factors. Scratches can occur from unsupported media and may be significant enough to require the drum to be replaced prior to the printer indicating the drum has reached its end of life. Paper which emits certain chemicals or large amounts of paper dust can cause excessive drum wear. If you this problem, contact your service representative or the paper manufacturer.

Fuser

The fuser yield is controlled by the number of times a letter or A4 sheet of paper passes through it. The printer maintains a counter which increments based on the size of paper used. Factors which may reduce fuser life can be related to printing repetitious images, media problems or not replacing the cleaning roller when necessary. Hewlett-Packard recommends mixing up the types and positions of print images printed among print jobs. Fuser rollers can wear unevenly when a dark image, such as a company logo or a thick dark line, is printed repeatedly in the same position on every page of every print job. Media can also have an effect on fuser life. Paper which emits certain chemicals or large amounts of paper dust can cause excessive wear. If you suspect problems of this sort, contact your service representative or the paper manufacturer. For optimum fuser life, replace the cleaning roller after every other bottle of toner, and follow the recommended cleaning procedures in “Duplex Area” on page 5-6. The cleaning roller deposits silicon oil onto the fuser roller surface to prevent toner from sticking. It also cleans away small amounts of toner that adhere to the fuser roller surface. Failure to replace the cleaning roller at the specified times can greatly reduce fuser yields. 6-10 Advanced Topics, Adjusting Paper Path Alignment

Advanced Topics Ozone Filter

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

Transfer Unit

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

Pushing Consumable Life Beyond Estimated Yields

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

Adjusting Paper Path Alignment

Over time, the paper path alignment may change slightly from the factory-set position. The following paper path alignment procedure will set the printing alignment for each tray to ensure correct print position. This procedure looks complicated, but after you have performed it a once or twice, it should only take a few minutes to complete. It may need to be repeated periodically to ensure proper alignment, but if you only print on blank paper, alignment is usually not critical. This procedure sets alignment for both simplex and duplex pages. If you have an HCI installed, you can also set alignment for it. Before proceeding, make sure that there is adequate (20 - 30 sheets) paper in each tray and the HCI (if installed). This amount is necessary for accurate feeding. Note Please read through the entire procedure before performing any of the steps. Advanced Topics 6-11, Adjusting Paper Path Alignment This procedure includes the following tasks: • Printing alignment sheets. When you run the alignment program from the printer’s hard drive, the printer produces a set of alignment pages. • Measuring alignment. By measuring the current alignment for each tray against a reference standard, you simply add two numbers to determine new alignment values. • Setting alignment values. Once you have determined new values, enter them in the Control Panel and recheck the alignment.

Printing Alignment Sheets

1. Verify that all three paper trays and the HCI (if installed) have Letter (or A4) size paper. 2. Press the Test button on the Main Screen, shown in Figure 6-3. Ready - - free 600dpi JUN 18 05:32.23

PCL LTR

LTR LTR Onfflliine LTR Offline Custom Menu Test PapSize Figure 6-3 Main Screen 3. Use N to scroll down and highlight filesC, as shown in Figure 6-4, and press Select. Test filesA filesC Online Online Select Figure 6-4 Test Submenu 6-12 Advanced Topics, Adjusting Paper Path Alignment

Advanced Topics

4. From the filesC submenu shown in Figure 6-5, use N to highlight USER_ADJ, then press Select. C:\ dir USER_ADJ\ PCLS\ PS\ MAINT\

Online FONTS\

Online Select Figure 6-5 FilesC submenu 5. Use N to highlight ALIGNSET.*, then press Select. The last two numbers refer to the program version number, which may be different from the version number shown in these illustrations. See Figure 6-6. C:\USER_ADJ\ dir ALIGNSET.12

Online

Online Select Figure 6-6 ALIGNSET.12 Advanced Topics 6-13, Adjusting Paper Path Alignment 6. The number 1 will appear in front of the ALIGNSET.* message, as shown in Figure 6-7. C:\USER_ADJ\ dir 1 ALIGNSET.12

Online

Online Select Figure 6-7 1 ALIGNSET.* 7. Press Online. Note After pressing Online, there will be a few seconds delay as the printer loads the program. The printer then produces six sheets: • a Simplex feed alignment ruler sheet. See Figure 6-8. • a set of alignment sheets, one from each tray (and the HCI if it is installed.) See Figure 6-9. • a Duplex unit alignment ruler sheet, which measures the duplex sideways and lengthwise alignment values (duplexv means "duplex vertical") See Figure 6-12. The Simplex feed alignment ruler sheet contains: • instructions for the alignment procedure • a reference scale to measure the alignment sheets • a workspace to calculate alignment values and adjustments When the printer has finished printing these pages, you are ready to begin measuring the alignment pages. 6-14 Advanced Topics, Adjusting Paper Path Alignment

Advanced Topics Measuring Alignment

You will now read the adjustment values. 1. Carefully and accurately, fold the top part of the Simplex feed alignment ruler sheet, shown in Figure 6-8. Adjustment scale Fold line Figure 6-8 Simplex Feed Alignment Ruler Sheet Advanced Topics 6-15, Adjusting Paper Path Alignment 2. On the alignment sheet for tray 1, shown in Figure 6-9, locate the Feed 1 alignment indicator line. 3. Place the simplex feed alignment ruler sheet adjustment scale between the ends of the arrows (at "measure between these two arrows", shown in Figure 6-9). Feed alignment indicator line

Feed 1: Upper tray Direction of paper motion

Measure between these two arrows Figure 6-9 Sample Alignment Sheet for Tray1 6-16 Advanced Topics, Adjusting Paper Path Alignment

Advanced Topics

4. Position the line labeled "Align with left edge of printed sheet" against the left edge of the alignment sheet for tray 1. Figure 6-10 shows how the two sheets should look when properly positioned. 5. The arrow printed on the alignment sheet for tray 1 will intersect the simplex feed alignment ruler sheet scale at some value, as shown in the illustration. Note Make sure that the tip of the arrow is on the exact edge of the paper. If it is not, your measurement may be inaccurate. Read measurement here Feed alignment indicator line Feed 1: Upper tray Place edge here Direction of paper motion Measure between these two arrows Line on printed sheet indicates the required relative adjustment. Direction of paper motion Figure 6-10 Measuring alignment with alignment scale -25 -20 -15 -10 -5 +5 +10 +15 +20 +25 Align with left edge of printed sheet Advanced Topics 6-17, Adjusting Paper Path Alignment 6. Record this value in the adjustment value area for tray 1 on the simplex feed alignment ruler sheet. See Figure 6-11.

Example

Original alignment value 14 currently in printer -5 Write in adjustment -5 value from line measurement Figure 6-11 Original alignment value and adjustment value 7. Repeat steps 2 through 4 with the alignment sheets for trays 2, 3, and the HCI (if installed). Note The printer still prints a sheet for the HCI even if no HCI is present. Simply ignore this page if you don’t have an HCI connected and paper installed in it. 8. Now read the values for duplex pages as directed in the next section. 6-18 Advanced Topics, Adjusting Paper Path Alignment

Advanced Topics

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

Lines printed on back side of sheet

Figure 6-12 Duplex Unit Alignment Ruler Sheet 1. On the duplex unit alignment ruler sheet, review each side of the paper. View through the paper: hold the paper up to a bright light with the side with the alignment scale facing towards you. 2. The sideways indicator line runs up and down the back of the page on the left. Look for the indicator line and note where it crosses the scale on the left. Record this value on sheet 1 at Duplex unit sideways alignment adjustment value. 3. The lengthwise indicator line runs across the back of the page. Look for the indicator line and note where it crosses the scale in the middle of the page. Record this value on sheet 1 at Duplex unit lengthwise alignment adjustment value. Advanced Topics 6-19, Adjusting Paper Path Alignment

Setting Alignment Values

You will now calculate and enter the new alignment values into the Control Panel. 1. Calculate the new values. 2. For each adjustment value, add the two numbers and write the new value, as shown in Figure 6-13. If the adjustment value you read off the sheet was 0, no new setting is required for that tray. -6 +8 +3 +15 -2 +14 -2 -2 0 No adjustment necessary +1 +7 +7 Figure 6-13 Adjustment values entered into work sheet 6-20 Advanced Topics, Adjusting Paper Path Alignment

Advanced Topics

Once you calculate the new value, enter it in the Control Panel as follows: 3. Press Menu on the Main Screen (see Figure 6-3). 4. Use N to highlight Maintenance, as shown in Figure 6-14, and press P. Menu Printing Configuration

PCL

Comms Maintenance Online Online Figure 6-14 Menu 5. From the Maintenance submenu shown in Figure 6-15, use N to highlight alignment and press P. Maintenance replace alignment density = 10 testpages = 30 monitor = OFF

Online date-time

Online Figure 6-15 Maintenance submenu Advanced Topics 6-21, Adjusting Paper Path Alignment 6. Select tray1 and press P. This is the Maintenance.alignment screen, shown in Figure 6-16. Maintenance.alignment tray1 = 5 tray2 = 6 tray3 = 5 duplex = -6 duplexv = -7

Online

Online Figure 6-16 Maintenance.alignment Tray1 setting 7. Press either M or N to highlight the tray1 new value calculated on the Simplex feed alignment ruler sheet. The selection range is from -25 to +25, (except for duplex lengthwise, which is +7 to -7). See Figure 6-17. Maintenance.alignment.tray1 = 5

Online 10

Online Select Figure 6-17 Tray1 values 8. Press Select to save the new value and to return to the Maintenance.alignment submenu. 9. Repeat steps 1 through 4 for trays 2, 3, HCI, duplex (duplex sideways), and duplexv (duplex lengthwise). 10. Verify your alignment by repeating the procedure in “Printing Alignment Sheets” on page 6-12. If the alignment is still off (plus or minus 3 to 4 increments or more), note the adjustment values as you did in the previous alignment procedure, and set the new adjustment values in the Control Panel. NoteA1or 2 increment variation may remain after alignment; this is normal. 6-22 Advanced Topics, Setting Up Edge-to-Edge Printing

Advanced Topics Setting Up Edge-to-Edge Printing

The D640 printer ordinarily enforces a 1/6" unprintable area around the edge of any page. This is the factory default and produces the best looking output. There may be some cases where you don’t want this border. The D640 supports edge-to-edge printing, which allows you to extend printing to the edge of the physical page. Note The print quality is not consistent within 1/6" of any edge. This is especially true for the trailing edge of the second side in duplex printing. For this reason, Hewlett-Packard cannot guarantee print quality within this 1/6" area. Your Hewlett-Packard warranty and service contract does not cover service calls related to printing within this 1/6" area. The quality and squareness of the paper determine print quality when printing close to the physical paper edge. In general, you may experience degraded print quality within .25 inches of any paper edge. When printing in duplex you may need to compensate for shrinkage and curl that may occur when the first side is printed. Lighter weight and recycled papers tend to shrink more then heavier weight papers. If you define text to start printing at location 0,0 it will print outside the logical page. This may or may not be on the physical page. Figure 6-18 describes the physical and logical page formats. Figure 6-18 Physical and Logical Page formats Advanced Topics 6-23, Configuring for LaserJet IIIsi and 4si Compatibility

Configuring for LaserJet IIIsi and 4si Compatibility

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

Paper Input

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

Example Configuration

LaserJet IIIsi / 4si • UPPER TRAY contains paper for job separation. • HCI TRAY contains white paper. - This configuration provides 500 sheets in the upper tray and 1500 sheets in the HCI tray. To match this configuration on the D640, set up the D640 as follows: • TRAY1 contains paper for job separation. • HCI contains white paper. • Set HCI-Alias = tray2. - This configuration provides 500 sheets in tray1 and 3000 sheets in the HCI. You could also load paper for job separation in tray2 and tray3 to increase capacity to 1500 sheets. 6-24 Advanced Topics, Configuring for LaserJet IIIsi and 4si Compatibility

Advanced Topics

If HCI-Alias is set to HCI, the values shown below in Table -6-1, “Paper tray map for HCI- Alias = HCI” are correct. If HCI-Alias is set to tray2, then you can send a job to either a 4si or a D640. Table 6-1 Paper tray map for HCI-Alias = HCI IIIsi, 4si D640 5si upper tray upper tray (tray1) upper drawer (tray2) lower tray middle tray (tray2) lower drawer (tray3) n/a High Capacity Input High Capacity Input n/a lower drawer (tray3) fold out tray (tray1) You can also set the default paper tray (used if there is no paper size or paper source command embedded in the print job) from the Control Panel. Use the intray setting in the Printing Menu.

Using the LaserJet 5Si Driver

The D640 printer can be used with a LaserJet 5Si printer driver, but there are many differences. For example: • The input tray selection is different. See Table 6-1 above. • The D640 printer does not support media type selection. • The LaserJet 5Si does not support font cartridges. Advanced Topics 6-25,

Using Virtual Font Cartridges Using Virtual Font Cartridges Each of the D640 internal fonts is almost identical to those used in the LaserJet 4si. Some

typefaces, treatments, and symbol sets are slightly different, due to advances in font technology since the development of the 4si. For example, if you print a very large question mark on each machine, you may notice differences in the shape.

All of the font sets from all of the 4si font cartridges sold by Hewlett-Packard are stored on the D640’s internal hard disk drive as virtual font cartridges. You select the virtual font cartridge

by the Control Panel vcartridge1 and vcartridge2 settings (see “Virtual Font Cartridges” on page 2-20). The font names are comparable to the actual physical cartridge.

Table 6-2 Virtual Font Cartridges Typeface and Treatment IIISi 4si C40D D640

Line Printer Med. bitmap bitmap bitmap bitmap Courier Med., Italic, Bold, Bold Italic bitmap Intellifont Intellifont Intellifont Letter Gothic Med., Italic, Bold nr Intellifont Intellifont Intellifont Arial Med., Italic, Bold, Bold Italic nr TrueType TrueType TrueType Symbol Med. nr TrueType TrueType TrueType Times New Roman Med., Italic, Bold, Bold Italic nr TrueType TrueType TrueType Wingdings Med. nr TrueType TrueType TrueType Albertus ExtraBold nr Intellifont Intellifont Intellifont Albertus Med. nr Intellifont Intellifont Intellifont Antique Olive Med., Italic, Bold nr Intellifont Intellifont Intellifont CG Omega Med., Italic, Bold, Bold Italic nr Intellifont Intellifont Intellifont CG Times Med., Italic, Bold, Bold Italic Intellifont Intellifont Intellifont Intellifont Clarendon Condensed Bold nr Intellifont Intellifont Intellifont Coronet nr Intellifont Intellifont Intellifont Garamond Antiqua nr Intellifont Intellifont Intellifont Garamond Halbfett nr Intellifont Intellifont Intellifont Garamond Kursiv nr Intellifont Intellifont Intellifont Garamond Kursiv Halbfett nr Intellifont Intellifont Intellifont Marigold. nr Intellifont Intellifont Intellifont Univers Condensed Med., Italic, Bold, Bold Italic Intellifont Intellifont Intellifont Intellifont Univers Med., Italic, Bold, Bold Italic Intellifont Intellifont Intellifont Intellifont ITC Zapf Dingbats Intellifont nr nr nr1 1. ITC Zapf Dingbats are available on the D640 Decorative Words I built-in cartridge. 6-26 Advanced Topics,

Print Messages A Printer Messages Printer Initialization Failure

In the unlikely event that the printer does not start correctly, follow these steps: 1. The printer may self-diagnose the problem and display the message as shown in Figure A-2, on page A-2. 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-9 to determine the mean- ing 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. If you can, print a test pattern, described in “Maintaining Print Quality” on page 6-1. 5. If you cannot resolve the problem, call your service representative, or refer to “Where To Call For Help” on page F-1 for the telephone number of your nearest Hewlett-Packard service representative. Be prepared to give the service representative the error code and any messages that appear on the Control Panel to assist in trouble- shooting.

Printer Reset

You can reset the printer without powering it off and on. This may be necessary if the printer is stopped and the Control Panel does not respond. Printer Messages A-1, Printer Messages To perform a printer reset, press function buttons 1, 3, and 5 (shown in Figure A-1 below) at the same time and release them. If the display goes blank and then returns in a few seconds, the reset worked. If the display does not go blank, then power off the printer by moving the main power switch to the OFF position. Wait 20 seconds and power the printer on. See “Powering On the Printer” on page 1-18 and Figure 1-10. 135Figure A-1 Press buttons to reset

Printer Messages

This appendix provides information about messages displayed on the printer’s Control Panel. There are several types of messages: • Status messages are reports about what the printer is doing and do not require any action. Table A-1 lists these messages. • Warning messages notify you when the life of a consumable is nearly over. Replace the consumable when convenient. Table A-2 lists these messages and directs you to the replacement procedure in this manual. • Paper jam messages occur when paper jams while moving along the printer’s paper path. Table A-3 lists these messages and directs you to the paper jam removal section in this manual. • Error messages indicate conditions that stop or prevent printing until the error is corrected. Table A-4 lists these messages and directs you to the replacement procedure in this manual. • Call Engineer error messages indicate conditions that may require a service representative to resolve. In some cases, you may be able to resolve these problems yourself, so refer to Table A-5 to interpret these error messages. This table includes corrective actions for each message. A-2 Printer Messages,

Status Messages Print Messages Status Messages The following is a list of normal status messages that will appear from time to time as you use

the D640. These messages provide status only and do not require any action by the operator.

The intention of these messages is to provide current printer status. Table A-1 Status messages Message Explanation

Printer Initializing The printer is performing self-diagnostics. Printer warming up The printer is heating the fuser unit for operation. Ready - free The printer is powered on and ready to use. No data has been received by the printer yet. Ready - printing The printer is currently feeding paper and physically imprinting the image on the paper. Ready - waiting The printer has received partial data and is waiting for the host send additional data. Ready - imaging The printer has received data and is building the page image. Ready - processing The printer is receiving data from the host. Error mask on The printer is operating with an error condition disabled. This can only be set or reset by your service representative. Menu Locked The menu has either been locked from a print job or the printer is processing a job and menu changes cannot be made.

Printer Messages A-3

,

Warning Messages Warning Messages The following warning messages indicate conditions that require operator intervention, such as

when the output tray fills up with paper, or when a particular consumable has reached the end of its life. The "end life" message remains until you replace the consumable. Always replace the consumable as soon as possible to maintain the best print quality.

Caution If you ignore the "Toner low" message, eventually the printer will shut down with

the "Toner empty" message to prevent mechanical damage.

Caution If you ignore the "Developer end-life" message, eventually the printer will shut

down with the "Developer end-life/Change developer at once" message to prevent mechanical damage.

Table A-2 Warning messages Message Explanation Action

Output tray full The printer’s output tray is full. Remove paper from tray. Paper-size mismatch The requested paper size is not Load correct paper size. available. Toner low The supply of toner in the toner Add toner. See “Replacing hopper is low. Developer” on page 4-9. Developer end-life The developer has reached the end Replace developer. See of its useful life and needs “Discharging Developer” on replacement. page 4-9. Drum end-life The drum has reached the end of See “Drum Kit - Replacing Drum (drum area blinks) its useful life and needs and Transfer Assembly” on replacement. page 4-18. Fuser end-life The fuser has reached the end of See “Removing the Fuser” on (fuser area blinks) its useful life and needs page 4-30. replacement. Tray 1 rollers end-life The indicated pick roller has See “Printer Pick Roller Kit - reached the end of its useful life Replacing the Tray Pick Rollers” Tray 2 rollers end-life and needs replacement. on page 4-33. Tray 3 rollers end-life HCI rollers end-life The HCI pick rollers have reached See “HCI Pick Roller Kit - the end of its useful life and need Replacing the HCI Pick Rollers” replacement. on page 4-42.

A-4 Printer Messages

, Paper Jam Messages

Print Messages Paper Jam Messages

Paper jam messages appear when there is a problem moving paper through the printer. One or more sheets of paper may be jammed. Refer to the Control Panel’s indication of the jam location and check Table A-3 below. If the jam message does not go away after removing the jammed paper, check the area again for stray paper fragments, and check the Control Panel. There may be more paper jammed at other locations in the paper path. WARNING! When you remove jammed paper, avoid contact with the paper sensors in the paper feed path. These small black plastic actuator levers are easily damaged. Table A-3 Paper jams and their remedies Refer to Paper Jam Messages Remedy page Loading Jams TRAY1 pick error Remove tray (1, 2, or 3), remove paper jam from paper entry page 3-24 TRAY2 pick error area and/or within the tray. TRAY3 pick error Feed path jam 1 Open the front door, lower transfer assembly, rotate knob 1 page 3-26 counterclockwise and knob 2 clockwise to free paper, remove jammed paper. Feed path jam 2 Open the lower right cover, remove jammed paper. page 3-26 HCI jam 1 Open HCI, lower paper, remove jammed paper. page 3-32 HCI jam 2 Pull HCI away from printer, remove jammed paper. page 3-34 HCI jam 3 Pull HCI away from printer, remove jammed paper. page 3-34 HCI jam 4 Open the front door, lower transfer assembly, rotate knob 1 page 3-26 counterclockwise and knob 2 clockwise to free paper, remove jammed paper. Paper Path Jams Fusing unit jam 1 Open the front door, lower transfer assembly, open lever 4, page 3-36 Fusing unit jam 2 push decurler lever down, remove jammed paper to right. Duplex path jam 1 Open the front door, raise lever 6, and remove jammed page 3-38 Duplex path jam 2 paper. You may need to turn duplex roller knob to release the paper. Print unit path jam (Reversing unit area jam) page 3-40 Open the front door, open lever 4, hold lever 5 away from the fuser, and remove jammed paper. You may need to turn duplex roller knob to release the paper. Printer Messages A-5,

Paper Jam Messages Refer to Paper Jam Messages Remedy

page Paper Ejection Jams

Ejection unit jam 1 Raise the paper ejection cover and remove jammed paper. page 3-43 Ejection unit jam 2 HCO jam 1 Open the HCO door, rotate roller knob 1 to free paper, then page 3-45 HCO jam 2 lift levers to remove paper. A-6 Printer Messages

,

Error Messages Print Messages Error Messages When any of the following error messages appear on the first line of the display screen, the

printer suspends printing until the error is corrected.

Table A-4 Error messages Message Explanation Action

Ejection unit cover open The ejection unit cover (on top Close the ejection cover until it of the printer) is open or not clicks shut. completely closed. Front Door open The front door is open or not Close the front door until it latches. completely closed. Upper right cover open The upper right cover is open or Close the upper right cover until it not completely closed. latches. Lower right cover open The lower right cover is open or Close the lower right cover until it not completely closed. latches. HCI cover open The HCI door is open or not Close the HCI door until it latches. completely closed. Fuser interlock The fuser is not seated Remove and reinsert the fuser into properly. the printer. See “Removing the Fuser” on page 4-30. Drum unit interlock The drum is not seated Remove and reinsert the drum into properly. the printer. See “Removing the Drum” on page 4-21. Developer collector not in The developer collector bottle is Remove and reinsert the developer (During developer replacement not seated properly or is collector bottle into the printer. See only) missing. “Installing Developer Collector Bottle” on page 4-16. Toner empty The toner hopper is out of Refer to “Replacing Toner” on page toner. 4-4 and install toner.

Printer Messages A-7

, Call Engineer Error Messages and Codes

Call Engineer Error Messages and Codes

Call Engineer error messages stop the printer and take it Offline. Some of these errors can be corrected by the user, but most require a visit from your service representative. Blinking Error code High-voltage power supply alarm Call Engineer (SVC 6F)

PCL LTR LTR

Offliine LTR Clear Menu End Figure A-2 Call Engineer (Service Representative) Before calling the service representative, follow these steps: 1. Try clearing the error by pressing Clear. 2. If the error condition persists, look up the error in “Call Engineer error messages and codes” on page A-9 and follow the instructions. 3. If the error condition persists, power the printer off and on to clear the error. 4. If the error condition persists, call your local service representative. A-8 Printer Messages,

Call Engineer Error Messages and Codes Print Messages Table A-5 Call Engineer error messages and codes Error Code Description Action Message

Pick motor 1 SVC 08 The upper tray’s pick motor Try clearing the error by pressing Clear. If alarm (tray 1) did not work correctly the error condition persists, call your local and may need to be service representative. replaced. Pick motor 2 SVC 09 The middle tray’s pick motor Try clearing the error by pressing Clear. If alarm (tray 2) did not work correctly the error condition persists, call your local and may need to be service representative replaced. Pick motor 3 SVC 0A The lower tray’s pick motor Try clearing the error by pressing Clear. If alarm (tray 3) did not work correctly the error condition persists, call your local and may need to be service representative. replaced. Switch-back SVC 0B The switch-back motor (just Try clearing the error by pressing Clear. If motor alarm left of the fuser) did not work the error condition persists, call your local correctly and may need to be service representative. replaced. Feed motor SVC 0D The feed motor (located on Try clearing the error by pressing Clear. If alarm the bottom) did not work the error condition persists, call your local correctly and may need to be service representative. replaced. Stacker select SVC 0E The solenoid switch in the Try clearing the error by pressing Clear. If alarm printer which controls paper the error condition persists, call your local output going to the HCO did service representative. not work correctly and may need to be replaced. Duplex motor SVC 0F The duplex motor did not Try clearing the error by pressing Clear. If alarm work correctly and may need the error condition persists, call your local to be replaced. service representative. Fuser alarm SVC 27 The fuser unit did not heat-up Confirm that the voltage rating on the fuser (time-out) to the normal fuser matches the voltage rating of the printer. temperature within the Verify that the fuser unit is correctly allotted warm up time. installed and that all printer doors and covers are closed, then press Clear. If the error message persists, refer to “Removing the Fuser” on page 4-30 and replace the fuser. If this error code returns, call your service representative. Fuser SVC 28 The fuser unit temperature is Verify that the fuser unit is correctly temperature above a normal level. installed and that all printer doors and high alarm covers are closed, then press Clear. If the error message persists, refer to “Removing the Fuser” on page 4-30 and replace the fuser. If this error code returns, call your service representative.

Printer Messages A-9

,

Call Engineer Error Messages and Codes Error Code Description Action Message

Fuser SVC 29 The fuser unit temperature is Verify that the fuser unit is correctly temperature below a normal level. installed and that all printer doors and low alarm covers are closed. Press returns, call from the front panel. If the error message persists, refer to “Removing the Fuser” on page 4-30 and replace the fuser. If this error code returns, call your service representative. Toner motor SVC 50 The motor which drops toner Open the upper right cover and check that alarm into the printer is not working the connector at the right side of the toner correctly and may need to be hopper is connected. If it is connected replaced. properly, call your service representative. Toner screw SVC 51 The waste toner auger is not To fix this error call your service rotation alarm working correctly and may representative. need to be replaced. Developer SVC52 During the developer To fix this error, call your service discharge replacement procedure the representative. alarm old developer might not be evacuated properly. The problem could be mechanical or electrical. Developer SVC54 During the developer To fix this error, call your service shutter alarm replacement procedure, the representative. shutter releasing the old developer did not open correctly. The problem could be mechanical or electrical. Toner auto- SVC 56 After the developer was Purge developer and try again with a new adjustment replaced, the automatic toner bottle. If this error code persists, call your alarm calibration could not be done service representative. correctly. The problem could be mechanical or electrical. Toner density SVC 57 The concentration of toner in Purge developer and try again with a new high alarm the developer unit is above bottle. If this error code persists, call your the normal range. service representative. Toner density SVC 58 The concentration of toner in Purge developer and try again with a new low alarm the developer unit is below bottle. If this error code persists, call your the normal range. service representative. Toner density SVC 59 The reference voltage used Purge developer and try again with a new voltage high to measure the toner bottle. If this error code persists, call your alarm concentration in the service representative. developer unit is above the normal range.

A-10 Printer Messages

,

Call Engineer Error Messages and Codes Print Messages Error Code Description Action Message

Toner density SVC 5A The reference voltage used Purge developer and try again with a new voltage low to measure the toner bottle. If this error code persists, call your alarm concentration in the service representative. developer unit is below the normal range. Toner hopper SVC 5B The hopper which holds the Confirm that the plastic protective cover on alarm toner is not working correctly, the right side of the toner hopper was or there is no toner in the removed (see page 2-47 of the D640 hopper. This error will occur Installation Manual). If you have recently if you continue to clear a added toner, call your service Toner Empty condition. representative. If you have not recently added toner, try adding toner. If the toner hopper is full, call your service representative. If the toner hopper was empty, cycle power after adding toner. Main motor SVC 69 The main motor did not reach Verify that the drum and fuser unit is alarm normal rotation speed. correctly installed and that all printer doors and covers are closed, then press Clear. If this error code returns, call your service representative. High-voltage SVC 6F The high voltage power Clean the transfer assembly charger (see power supply supply is not working “Transfer Assembly Guide” on page 5-9) alarm correctly. and try to print again. If the error persists, try replacing the transfer unit (see “Removing the Transfer Assembly” on page 4-19). If the error still persists, try replacing the drum unit (see “Drum Kit - Replacing Drum and Transfer Assembly” on page 4- 18). If the error persists after replacing the drum unit, call your service representative. Spindle motor SVC 79 The motor inside the optical Turn the printer off for at least 30 seconds, alarm unit did not reach the normal and turn the printer on again. If this error rotation speed. code returns, call your service representative. BD1 alarm SVC 7A The BD (beam detection) Turn the printer off for at least 30 seconds, signal number 1, inside the and turn the printer on again. If this error optical unit is not working code returns, call your service correctly. representative. BD2 alarm SVC 7B The BD (beam detection) Turn the printer off for at least 30 seconds, signal number 2, inside the and turn the printer on again. If this error optical unit is not working code returns, call your service correctly. representative. BD speed high SVC 7C The BD (beam detection) Turn the printer off for at least 30 seconds, alarm cycle, inside the optical unit and turn the printer on again. If this error is above normal speed. code returns, call your service representative.

Printer Messages A-11

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Call Engineer Error Messages and Codes Error Code Description Action Message

BD speed low SVC 7D The BD (beam detection) Turn the printer off for at least 30 seconds, alarm cycle, inside the optical unit and turn the printer on again. If this error is below normal speed. code returns, call your service representative. LD alarm SVC 7E The LD (laser diode), inside Turn the printer off for at least 30 seconds, the optical unit is not working and turn the printer on again. If this error correctly. code returns, call your service representative. In-frame fan SVC A0 Fan number 1 (inside the Turn the printer off for at least 30 seconds, alarm 1 optical unit) did not rotate and turn the printer on again. If this error correctly. code returns, call your service representative. In-frame fan SVC A1 Fan number 2 (upper left rear Turn the printer off for at least 30 seconds, alarm 2 side) did not rotate correctly. and turn the printer on again. If this error code returns, call your service representative. In-frame fan SVC A3 Fan number 6 (fan for Turn the printer off for at least 30 seconds, alarm 6 cooling the main controller and turn the printer on again. If this error board) did not rotate code returns, call your service correctly. representative. In-frame fan SVC A4 Fan number 7 (lower left rear Turn the printer off for at least 30 seconds, alarm 7 side) did not rotate correctly. and turn the printer on again. If this error code returns, call your service representative. Watchdog SVC B0 The timer on the mechanism Turn the printer off for at least 30 seconds, timer alarm controller board was not and turn the printer on again. If this error (master) reset by the “Master CPU”. code returns, call your service Turn the printer off for at representative. least 30 seconds, and turn the printer on again. If this error code returns, call your service representative. Watchdog SVC B1 The timer on the mechanism Turn the printer off for at least 30 seconds, timer alarm controller board was not and turn the printer on again. If this error (slave) reset by the “Slave CPU”. code returns, call your service Turn the printer off for at representative. least 30 seconds, and turn the printer on again. If this error code returns, call your service representative. Communicatio SVC B3 The communication Turn the printer off for at least 30 seconds, n alarm between the two processors and turn the printer on again. This error is on the mechanism controller not related to the serial or parallel ports. If board was disabled. this error code returns, call your service representative.

A-12 Printer Messages

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Call Engineer Error Messages and Codes Print Messages Error Code Description Action Message

EEPROM SVC B4 The mechanism controller Turn the printer off for at least 30 seconds, alarm detected a problem with the and turn the printer on again. If this error NVRAM (EEPROM). code returns, call your service representative. VS alarm SVC B5 A return signal from the main Turn the printer off for at least 30 seconds, controller was not received and turn the printer on again. If this error by the mechanism controller code returns, call your service during the normal response representative. time. Prepick alarm SVC B6 A return signal from the main Turn the printer off for at least 30 seconds, controller was not received and turn the printer on again. If this error by the mechanism controller code returns, call your service during the normal response representative. time. VR alarm SVC B7 A return signal from the Turn the printer off for at least 30 seconds, (time-out) mechanism controller was and turn the printer on again. If this error not received during the code returns, call your service normal response time. representative. HCI table SVC C4 The HCI encountered an Refer to “Clearing HCI Jams” on page 3-32 decent alarm error when the HCI’s table to locate and remove any paper that may be was being lowered. jammed inside the HCI. Look for any paper stuck at the lower left side as you open the HCI’s door. Reattach the HCI to the printer and close the HCI’s door. Press Clear. If this error code returns, call your service representative. HCI table SVC C5 The HCI encountered an Refer to “Clearing HCI Jams” on page 3-32 ascent alarm error when the HCI’s table to locate and remove any paper that may be was being raised. jammed inside the HCI, in particular look for any paper stuck at the lower left side as you open the HCI’s door. Reattach the HCI to the printer and close the HCI’s door. Press Clear. If this error code returns, call your service representative. HCO stacker SVC D8 This code indicates an error Verify the following: alarm with the HCO. (1) the HCO interface cable is connected to the printer, (2) the HCO’s power cable is plugged into an working AC outlet, and (3) the HCO’s power switch is turned on. (Refer to the D640 Installation Manual for this information). Press Clear. If this error code returns, call your service representative. Disconnect the HCO interface cable and power the printer off and on to continue using the printer without the HCO.

Printer Messages A-13

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Interface Configuration B Host Serial and Parallel Interface Configuration Introduction

The D640 printer is equipped with two standard communication interfaces used to connect to a host computer: • Bitronics (Parallel) interface • RS-232C serial interface With the addition of an HP JetDirect EX interface, purchased separately, you can use the printer on a local area network (LAN). The JetDirect EX interface connects the network to the Bitronics interface of the printer. (If you purchased the HP JetDirect EX interface, you’ll find detailed directions included in the JetDirect EX Configuration Guide.) Parallel connector Serial connector Figure B-1 Standard Signal Interface Connectors The standard parallel (IEEE 1284C) and serial (RS-232C) communication interface connectors are located on the back of the printer, as shown in Figure B-1. The IEEE 1284C connector is at the upper back of the printer; this connector is smaller than the usual (Centronics) parallel Host Serial and Parallel Interface Configuration B-1, Using the Serial Interface connector. This is a “C” type Bitronics connection. Hewlett-Packard has included an “A-to-C” parallel printer cable with the printer. The RS-232C connector is the standard DB25 pin connector, located near the top center of the printer. You can get more information about HP’s compliance with the IEEE 1284 Standard from the HP FIRST fax retrieval service at 1-800-333-1917 in the USA and Canada. Ask for document number 1951. The same document is also available by ftp from: ftp://ftp-boi.external.hp.com/pub/printers/laserjet/doc/bp02455.asc

Using the Serial Interface

Use the serial interface when you need to locate the printer at some distance (up to 50 feet (15 meters)) from the host computer. You can use either an RS-232C or an RS-422A cable. Table B-1 lists RS-232C and RS-422A pin assignments and signal descriptions. Those pins not listed in the table are not used. Table B-1 Pin assignments for a serial cable Pin Description RS-232 RS-422 I/O Number 1 Protective ground. * * - 2 Transmitted data (data from printer). * n/a Output 3 Received data (received by printer). * n/a Input 3 (RS-422) Received data inverted (RDA) (received by printer). n/a * Input 4 Request to send. This signal is HIGH when the * n/a Output printer is on. 7 Signal ground. * * 9 (RS-422) Send data inverted (SDA). n/a * Output 10 (RS-422) Send data non-inverted (SDB). n/a * Output 14 Must be connected to ground (7) to select RS-422 n/a * Input mode (SDB). 18 (RS-422) Receive data non-inverted (RDB). n/a * Input 20 Data terminal ready * n/a Output * = valid signal n/a = unimplemented B-2 Host Serial and Parallel Interface Configuration, Using the Serial Interface

Interface Configuration

The serial interface is accessible through a 25-pin female connector (Figure B-2) at the back of the printer. The interface can be configured to operate in an RS-232 or RS-422 configuration. Use the control panel to set the configuration. If you are set up for RS-232 operation, you can convert to RS-422 operation by shorting pin 14 of the interface to ground (pin 7). (RS-232 interface) (RS-422 interface) FGround 1 FGround 1 TxD 2 14 *422Sel 2 14 *422Sel RxD 3 15 RxDA 3 15 RTS 4 16 4 16 5 17 5 17 6 18 6 18 RxDB Ground 7 19 Ground 7 19 8 20 DTR 8 20 9 21 TxDA 9 21 10 22 TxDB 10 22 11 23 11 23 12 24 12 24 13 25 13 25 Figure B-2 RS-232 and RS-422 Host Interface Connectors pin diagram Host Serial and Parallel Interface Configuration B-3, Using the Parallel Interface

Using the Parallel Interface

The parallel interface uses a 36-pin connector (Figure B-3) at the back of the printer. It is an IEEE 1284 Type C parallel connection. Signal names on the following connector pin assignment diagram relate to Centronics operating mode. Busy 1 19 Ground Select 2 20 Ground Ack 3 21 Ground Fault 4 22 Ground P error 5 23 Ground Data1624 Ground Data2725 Ground Data3826 Ground Data4927 Ground Data 5 10 28 Ground Data 6 11 29 Ground Data 7 12 30 Ground Data 8 13 31 Ground Init 14 32 Ground Strobe 15 33 Ground Select in 16 34 Ground Auto Feed 17 35 Ground NC 18 36 Peripheral logic hi Figure B-3 Parallel Host Interface Connector pin diagram B-4 Host Serial and Parallel Interface Configuration, ecifications

C Specifications and Regulatory Information Introduction

This chapter provides specifications, safety compliance, options, and printing paper for the HP5000 family D640 cut sheet printer and accessories. If you want to: Go to: • Printer specifications page C-2 • Printable area specifications page C-6 • Summary of printer options specifications page C-7 • HCI specifications page C-7 • HCO specifications page C-10 • Custom tray specifications page C-12 • Postscript upgrade page C-12 • Safety information page C-13 • Regulatory information page C-13 • Safety standards page C-15 • General considerations page C-15 Specifications and Regulatory Information C-1

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, Printer Specifications

Printer Specifications

This section provides general, print speed, physical, electrical, and environmental specifications as well as safety standards. Table C-1 lists general specifications for your D640 printer. Table C-1 Printer general specifications Item Specifications Printing Laser diode, electro-photographic technology Printing speed 40 ppm (Letter and A4 landscape) Size Letter, Legal, Ledger. Executive, A3, A4, A5, B4 (JIS), B5 (JIS) Paper Type Plain Paper, Label paper, Recycle paper, Transparency paper, Bond paper, Pre-punched paper Resolution 600 × 600 dpi • 3 trays × 500 sheets (64 g/m2) standard Paper capacity • 1 tray x 500 sheets (64 g/m 2) optional custom tray • 3,000 sheets (A4, Letter size only) optional High Capacity Input (HCI) • 500 sheets (64 g/m2) face down tray Stacker capacity • 2,000 sheets optional High-Capacity Output Emulation PCL, HEX, optional PostScript (PS) Interface 2 ports (Serial RS232C/422A and Parallel IEEE 1284C) Warm-up time Less than 150 seconds First print time Less than 18 seconds Resident RAM 16 MB (Expandable to 64 MB) Resident font Bitmap font: 1, Outline fonts: 45 C-2 Specifications and Regulatory Information,

Printer Specifications

ecifications

Table C-2 lists D640 printer print speeds for various paper sizes. Table C-2 Printer print speed specifications From Tray 1, 2, 3 Paper Size or HCI Simplex Duplex

Letter 40 40 Legal 25 15 Ledger 21 15 Executive 40 40 A3 21 15 A4 40 40 A5 40 40 B4 (JIS) 24 24 B5 (JIS) 30 30 Custom (width = 120mm to 297mm, 40 40 length = 182mm to 215.9mm) Custom (width = 120mm to 297mm, 21 15 length = 215.9mm to 431.8mm) Notes: 1. Unit of measure: Images Per Minute (IPM) 2. In Simplex and Duplex Modes, all the speeds have ±5% tolerance.

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

Dimensions Width Depth Height 570 mm (22.5 in) 630 mm (24.8 in) 1,030 mm (40.6 in) Weight Approximately 130 kg Service area Front Back Left Right 650 mm (25.6 in) 850 mm (33.5 in) 850 mm (33.5 in) 850 mm (33.5 in)

Specifications and Regulatory Information C-3 Sp

, Printer Specifications Figure C-1 illustrates the physical specifications and Figure C-2 illustrates the required printer service area dimensions. 40.5 in. (1030 mm)

LTR LTR LTR

23.0 in. 1.38 in 25.2 in. (585 mm) (35 mm) (640 mm) Figure C-1 D640 Printer Physical Dimensions C-4 Specifications and Regulatory Information, Printer Specifications ecifications 33.5 in. (850 mm) 84.3 in. (2140 mm) Printer 25.2 in. (640 mm) Operating 25.6 in. Side (650 mm) 33.5 in. 23.0 in. 33.5 in. (850 mm) (585 mm) (850 mm) 90.0 in. (2285 mm) Figure C-2 D640 Printer required service area dimensions Table C-4 Printer electrical specifications Item Specifications Voltage 120 to 127 VAC ± 10%, 12A 200 to 240 VAC ± 10% 7A Input power Phase Single-phase Frequency 50/60Hz ± 5% Power consumption 1,300 VA or less than during operating Heat production 894 kcal per hour (3550 Btu per hour) In-rush current Up to 100 amps Note If the printer is connected to a line conditioner, make sure the line conditioner can support the in-rush current requirement for the printer. Specifications and Regulatory Information C-5

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, Printer Specifications Table C-5 Printer environmental specifications Item Specification Ambient Conditions Operating Non-operating Temperature 15 to 35°C 0 to 35°C Humidity 20 to 80% RH 20 to 80% RH (no condensation) (no condensation) 40 to 60% RH optimal 40 to 60% RH optimal Maximum wetbulb temperature 29°C (no condensation) Temperature and humidity gradients 15 °C per hour or less and 30% RH per day or less (no condensation) Acoustic noise See Table C-15 for details. Dust 0.15 mg./m (stearic acid) Ozone emission 0.1 PPM or less

Best Printing Area Specifications

Place your printed image in an area within a 1/6 inch (4.23 mm) border. Printing outside of this boundary may be of lower quality. Figure C-3 shows the best printing area. Margin Best area Figure C-3 Best printing area If data is printed outside the best printing area, you may obtain poor print quality. C-6 Specifications and Regulatory Information, D640 Optional Accessories ecifications

D640 Optional Accessories

Table C-6 lists printer options and their associated specifications. Table C-6 D640 printer options and specifications summary Item Specification Part Number High-Capacity Input (HCI) 3,000 sheets (20 lbs; 64 g/m2) C5621A (Letter) C5622A (A4) High-Capacity Output (HCO) 2,000 sheets (20 lbs; 64 g/m2) C5623A (120 V) C5624A (200 - 240) Custom paper tray 500 sheets (at 75g/m2) C5634A Standard paper tray 500 sheets (at 75g/m2 C5625A PostScript upgrade PostScript Level 2 C5630A (includes 16 MB memory) 16 MB Memory Kit 16 MB SIMM (maximum 3 SIMMs) C5635A

High Capacity Input (HCI) Specifications

The C5621A and C5622A are user-installable high capacity input (HCI) paper hoppers. C5621A uses Letter size paper only and the C5622A uses A4 size paper only. Figure C-4 illustrates the C5621A/C5622A high capacity input hopper. 11.3 ( in2 .87 mm) 17.6 ( in4 .46 mm) Printer 22.2 ( in5 .62 mm) Figure C-4 High Capacity Input physical dimensions Specifications and Regulatory Information C-7

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, High Capacity Input (HCI) Specifications Table C-7 lists the HCI paper related specifications. Table C-7 HCI paper handling specifications Item Specifications Processing speed 40 ppm (C5621A: Letter landscape, C5622A: A4 landscape) Size C5621A: Letter / C5622A: A4 Paper Type Plain paper, Label paper, Bond paper, Pre-punched paper, 64 to 90g/m2 Paper capacity 3,000 sheets (75g/ m2) Table C-8 lists the HCI physical dimensions, unit weight, and required service area dimensions and Figure C-4 illustrates these dimensions. Figure C-5 illustrates the HCI service area requirements. Table C-8 HCI physical specifications Item Specification Width 11.3 in (287 mm) Dimensions Depth 17.6 in (446 mm) Height 22.2 in (562 mm) Weight About 38 lbs (17 kg) Front 25.6 in (650 mm) Service area Back 33.5 in (850 mm) Right 33.5 in (850 mm) C-8 Specifications and Regulatory Information, High Capacity Input (HCI) Specifications ecifications 33.5 in. (850 mm) 84.3 in. (2140 mm) HCO Printer HCI 25.2 in. (640 mm) Operating 25.6 in. Side (650 mm) 33.5 in. 23.0 in. 33.5 in. (850 mm) (585 mm) (850 mm) 21.25 in. 11.38 in. (540 mm) (289 mm) 122.6 in. (3114 mm) Figure C-5 HCO (left), D640 Printer (center), and HCI (right) required service area dimensions

HCI Electrical Specifications

Table C-9 lists the HCI electrical specifications. Table C-9 HCI electrical specifications Item Specification Input power 24VDC, supplied from D640 printer Power consumption 30VA or less during operating Specifications and Regulatory Information C-9

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, High Capacity Output (HCO) Specifications

High Capacity Output (HCO) Specifications

Figure C-6 shows the user-installable high capacity output (HCO). Model number C5623A is the 120VAC version, and model number C5624A is the 240VAC version. The HCO can stack up to 2000 sheets of paper. 16.1 in. (408 mm ) 17.4 in . m) (442 m . 36.0 in m) m (913 Printer Figure C-6 High Capacity Output physical dimensions

HCO Paper Handling Specifications

Table C-10 lists the HCO paper handling specifications. Table C-10 HCO paper handling specifications Item Specifications Processing speed 40 ppm Size Letter, Legal, Ledger, Executive, A3, A4, A5, B4(JIS), B5(ISO) Paper Type Plain paper, Label paper, Transparency, Bond paper, Pre-punched paper, 64 to 90g/m2 Paper capacity 2,000 sheets (75g/ m2) C-10 Specifications and Regulatory Information, High Capacity Output (HCO) Specifications ecifications

HCO Physical Specifications

Table C-11 lists the HCO physical dimensions, unit weight, and also provides the required service access area dimensions. Figure C-6 illustrates these specifications. Table C-11 HCO physical specifications Item Specification Width 16.1 in, 408 mm Dimensions Depth 17.4 in (446 mm) Height 36.0 in, 913 mm Weight About 70 lbs (32 kg) Front 25.6 in (650 mm) Service area Back 33.5 in (850 mm) Right 33.5 in (850 mm)

HCO Electrical Specifications

Table C-12 lists the HCO electrical specifications. Table C-12 HCO electrical specifications Item Specifications Voltage 100 to 120 VAC ± 10%, 200 to 240 VAC ± 10% Input power Phase Single-phase Frequency 50/60Hz Power consumption 120 VA or less than during operating Heat production 83 kcal per hour Specifications and Regulatory Information C-11

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, Printer Custom Paper Tray Specifications

HCO Environmental Specifications

Table C-13 lists the HCO environmental specifications. Table C-13 HCO environmental specifications Ambient Condition Operating Non-operating Temperature 15 to 35 °C 0 to 35 °C Humidity 20 to 80% RH 20 to 80% RH (no condensation) (no condensation) 40 to 60% RH optimal 40 to 60% RH optimal Temperature and 15 °C per hour or less and 30% RH per day or less (no humidity gradients condensation)

Printer Custom Paper Tray Specifications

The C5634A custom paper tray is a user-installable, optional paper tray compatible and switchable with any of the standard printer paper trays. The custom paper tray can hold up to 500 sheets of paper, as listed in the Table C-14 specifications. Table C-14 Custom paper tray physical specifications Minimum Maximum Width 120 mm 297mm Length 182 mm 431.8 mm The paper guides in the custom paper tray are adjustable, and it also supports the following standard media sizes: Letter, Legal, Ledger, Executive, A3, A4, A5, B4 and B5.

PostScript Upgrade

The C5630A PostScript upgrade is a user-installable optional upgrade for PostScript Level 2 emulation. You can add PostScript to your D640 printer with the C5630A PostScript upgrade. If you add PostScript, you must also install another 16 MB of printer memory (included with the C5630A PostScript upgrade kit). C-12 Specifications and Regulatory Information, Safety and Regulatory Information ecifications

Safety and Regulatory Information

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

FCC Statement (USA only)

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

DOC Statement (Canada only)

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

Europe RFI Statement

This is a Class A product. In a domestic environment, this product may cause radio interference, in which case the user may be required to take adequate measures. Specifications and Regulatory Information C-13

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, Safety and Regulatory Information

Acoustics Emissions

Table C-15 Acoustic noise levels per ISO 9296, with HCI and HCO With HCO Power Save Operation Printer Only and HCI Mode Bystander (while printing) 56 dB(A) 58 dB(A) - Bystander (in standby mode) 52 dB(A) 52 dB(A) 33 dB(A) Sound Power (while printing) 7.4 bels(A) 7.7 bels(A) - Sound Power (in standby mode) 6.6 bels(A) 6.6 bels(A) 4.5 bels(A)

Data Communications (United Kingdom only)

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

Material Safety Data Sheets

Hewlett-Packard has Material Safety Data Sheets (MSDS) available for all chemicals associated with the printing process implemented by all HP products. Should your site require a Material Safety Data Sheet for an HP-supplied chemical in use at your site, please contact HP at 1-800-752-0900 in the US (or 613-820-6483 in Canada) or your local HP service office, and provide the following information: • HP part or product number • Chemical substance description • Your name • Company name • Company address • Telephone number • FAX number, if the request if for a FAX copy C-14 Specifications and Regulatory Information, Safety Standards and General Considerations ecifications

EPA Energy Star Computer Compliance

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

Safety Standards and General Considerations

This printer has been designed to conform to recognized technical standards, including the following national and international product safety standards and norms: • CSA C22.2 No. 950 • EN 60950 (IEC 950) • EN 60825 (IEC 825) • UL 1950 • U.S. CDRH 21CFR Ch.1 Subch J Any unauthorized removal of safety covers, manipulation of safety switches, and interference with the safety system is strictly prohibited. Such actions can cause personal injury and can damage the system. Also make sure that the operating and maintenance areas are not obstructed in any way. Specifications and Regulatory Information C-15

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, Laser Safety Standards

Laser Safety Standards Printer Laser Equipment Compliance Label

This product is a Class I laser product. The laser safety label is located on the top of the optical unit. DANGER INVISIBLE LASER RADIATION WHEN OPEN AND INTERLOCK FAILED OR DEFEATED. AVOID DIRECT EXPOSURE TO BEAM ATTENTION EXPOSITION AU LASER INVISIBLE SI OUVERT OU SI LE VERROUILLADE EST DEFECTUEUX EVITER L’EXPOSITION DIRECTE AU RAYON DE LASER. VORSICHT UNSICHTBARE LASERSTRAHLUNG. WENN ABDECKUNG GEOFFNET UND SICHERHEITSVERRIEGELUNG UBERBRuCKT NICHT DEM STRAHL AUSSETZEN. FARA Risk för stråining av osynilgt laserljus om såkerhetsorytare är ur funktion då tuckan öppnas.

Laser Safety Statement (USA Only)

The Center for Devices and Radiological Health (CDRH) of the U.S. Food and Drug Administration has implemented regulations for laser products manufactured since August 1, 1976. Compliance is mandatory for products marketed in the United States. This printer is certified as a “Class 1” laser product under the U.S. Department of Health and Human Services (DHHS) Radiation Performance Standard according to the Radiation Control for Health and Safety Act of 1968. Since radiation emitted inside this printer is completely confined within protective housings and external covers, the laser beam cannot escape during any phase of normal user operation. Caution Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure. C-16 Specifications and Regulatory Information, Laser Safety Standards ecifications

Laser Safety Statement (Finland Only) LASERTURVALLISUUS LUOKAN 1 LASERLAITE KLASS 1 LASER APPARAT

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

VAROITUS !

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

VARNING !

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

HUOLTO

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

VARO !

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

VARNING !

Om laserprinterns skyddshölje öppnas då apparaten är i funktion, utsättas användaren för osynlig laserstrålning. Betrakta ej stralen. Tiedot laitteessa käytettävän laserdiodin säteilyominaisuuksista: Aallonpituus 780 nm Teho 5 mW Luokan 3B laser Specifications and Regulatory Information C-17

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, HP Declaration of Conformity

HP Declaration of Conformity

C-18 Specifications and Regulatory Information,

Using Paper D Using Paper

The D640 prints on a variety of print media, including paper, labels, and overhead transparencies, at up to 600 x 600 dots per inch (dpi). Note The D640 does not accept envelopes as print media. The D640 printer uses laser electrophotographic technologies. In this process, a laser writes an electrostatic image onto the photosensitive drum. As this image passes the developing station, a dry, powdery toner is attracted to the imaged areas. This developed image then advances to the transfer station, where the belt contacts the media and the toner image is electrostatically transferred onto the paper. After transfer, the media passes through the fuser; heat and pressure are applied and the toner fuses (melts) onto the media. The media is then deposited in the output tray, ready for use. To create the printed image all print media must be transported through the printer, electrostatically charged, and heated. This is why media properties such as electrical resistivity, caliper, smoothness, and stiffness can affect the print quality and media handling performance of your D640 printer.

Supported Print Media Types

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

Alternate Sources of Information

The manufacturer and the vendor of the media that you select should be able to provide information about the suitability of its use in a D640 printer. Your vendor should be your contact when selecting media for your individual application needs. If you have tried all of the suggestions outlined in this document, and still need assistance, HP provides support through the world-wide network of Hewlett-Packard Sales and Service Offices. Refer to “Warranty and Support” on page F-1. Using Paper D-1, Paper Manufacturing In the United States, Hewlett-Packard also offers support through a local support representative. A customer support technician will be happy to offer advice to help solve your printer operation problems.

Paper Manufacturing

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

Sources of Paper

Paper is primarily made from cellulose fiber, the major component of the cell walls of wood fibers and other plants. Sources of this fiber include: • Raw Wood • Recycled or waste wood • Cotton Pulping methods are based, in part, on the fiber length of the raw wood. Hardwoods, such as cottonwood, contain short fibers, from one to two millimeters in length. Softwood fibers, including pine, spruce, and other conifers range in length from three to six millimeters. In each case, the thickness is less than that of a human hair. These differences often mean variability among paper manufacturers, even within the same company. To ensure quality and consistency, a certain percentage of this material must come from raw wood. Timber may be harvested from national forests and private land as well as tree farms or plantations. Surface Coatings A thin layer of coating may be applied to the paper which could change its physical characteristics. These surface coatings or “sizings” are added to make the sheets more resistant to ink or water penetration and to increase durability. Coatings may also be added to create a neutral pH in paper used for archival storage (such as legal documents). Surface coatings are usually liquid starches and are applied either by spraying, immersion, or mixing into the furnish. Heavy coatings of clay or talc should be avoided because they become hard and brittle, causing the fibers to break like a piece of chalk and come off during printer operation. Surface coatings also affect the surface electrical resistivity, which is a important factor in the performance of your D640 printers. D-2 Using Paper, Media Selection Specifications and Guidelines

Using Paper

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

Packaging

Packaging is an important step in the paper-making process. Much of the paper used for computing printing applications is packaged in reams: wrapped bundles containing 500 sheets. Because paper is hygroscopic, or capable of absorbing or losing moisture from the air, it should be protected by moisture-proof polylaminated wrapping and moisture barriers. A ream of finished paper usually contains about 4% moisture. The paper ream remains stable if properly stored and opened only when ready to be used. Paper Ream Label A ream label is placed on the outside of the paper wrapping. The ream label usually indicates paper: basis weight, size, number of sheets, grain direction and grade. The printing surface of the paper may be indicated by an arrow on the ream label. Paper should be loaded into the printer so that surface indicated by the arrow will be the printing surface. The printing surface may be up or down, depending on the printer model and the paper feeding source. Figure D-1 Ream Label

Media Selection Specifications and Guidelines

Hewlett-Packard neither warrants nor recommends the use of a particular print media. Media properties are subject to change by manufacturers and Hewlett-Packard has no control over such changes. The customer assumes all responsibility for the quality and performance of media. Although testing media helps to characterize their performance, long-term satisfaction requires process quality control by the manufacturer and proper handling until use. Using Paper D-3, Media Selection Specifications and Guidelines

Recommendations to the Customer

Hewlett-Packard D640 printers are designed to be as flexible as possible in the types of print media they can use. Since there are many varieties of media and variations in the manufacturing process, you should test a particular medium in your environment to determine if it performs acceptably. Buy Media that Meets Specifications To get the best performance from your D640 printer, select high quality print media that meet the guidelines and specifications in this document. Test Small Amounts of Media The next step in choosing media, particularly if you are planning a large purchase, is to print a small quantity in your environment. Subject it to the temperature, humidity, and printing application in which it will be operating. DO NOT purchase large quantities without first testing the media! Hewlett-Packard recommends that you ask your media vendor for a guarantee that their media will perform satisfactorily in your D640 printer, and that you ask the vendor to assume responsibility for the replacement of any media that will not print acceptably. Use High Quality Media Hewlett-Packard printers will work best with high quality media. Quality media for D640 printers are characterized by uniform physical properties, freedom from dust and lint, accurate cutting to size, and packaging that protects it from moisture and physical damage. Curled or bent edges, spots, dust or lint, wrinkling, and inaccurate cutting to size are common media problems that should be avoided. These problems can cause misfeeding, jamming, premature wear, or unsatisfactory print quality. Size Table D-1, “Paper sizes” shows paper sizes that can be used with D640 printers. Shown also is the numeric code displayed on the operator panel for each paper size. All paper sizes can be used in either simplex or duplex printing modes. Use only paper that is within the dimensions shown in Table D-1, “Paper sizes”. Note Although the D640 printer can print over the entire sheet, we do not guarantee quality for print in the outer 5mm of the page periphery. This border will vary slightly with the quality of the paper used. Table D-1 Paper sizes Size Dimensions A3 11.69 X 16.53 in. 297 X 420 mm A4 8.26 X 11.69 in. 210 X 297 mm D-4 Using Paper, Media Selection Specifications and Guidelines

Using Paper

Table D-1 Paper sizes Size Dimensions A5 5.84 X 8.26 in. 149 X 210 mm JIS B4 10.11 X 14.32 in. 257 x 364 mm JIS B5 7.16 X 10.11 in. 182 X 257 mm Letter 8.5 X 11 in. 216 X 280 mm Legal 8.5 X 14 in. 216 X 356 mm Ledger 11 X 17 in. 280 X 432 mm Executive 7.25 X 10.5 in. 184 X 267 mm Basis Weight Basis weight is an important characteristic to consider because, paper that is too light or too heavy may cause misfeeds, mis-stacking, paper jams, or excessive mechanical wear. The printer is specifically designed to perform at maximum efficiency when 20 pound bond (75g/m2) paper is used. Optimum print quality and paper path reliability are achieved when high quality electrophotographic (EP) paper is used. EP papers have specific characteristics that distinguish them from bond papers. The range of paper weight that the printer and HCI can process is 17 to 24 pound (64 to 90 g/m 2). The printer can handle paper weights up to 36 pound (135 g/m2), but 17 to 24 is optimum. Specifications for basis weight depend upon the paper source the paper is fed. In general, the straighter the paper path, the heavier the basis weight may be. For more complex paper paths, as in feeding from the HCI, a lighter weight may be required, in range of 18 to 24 pound. Furnish (Composition) Furnish is the fiber and chemical composition of paper. Fiber composition of the paper used in D640 printers should be manufactured from 100 percent chemical wood pulp and/or cotton fiber. To ensure that paper of a special fiber composition will work properly, always test it before purchasing large quantities. Other allowable components of paper are sizing, fillers, buffers and pigments. Note DO NOT use coated paper or paper containing materials that melt, vaporize, offset, discolor or release hazardous emissions when exposed to 392°F (200°C). Using Paper D-5, Media Selection Specifications and Guidelines Curl Curl is curvature in a sheet of paper. Curl is typically measured by laying the sheet of paper on a flat surface, with the corners up, and measuring the height of the corners. In-ream curl is the amount of curl a sheet of paper has before printing. (In-ream curl may result from the paper manufacturing process or from exposure to the environment). Post-image curl is the amount of curl a sheet of paper has after printing (from exposure to the fusing process and paper path in the printer). Paper with excessive in-ream curl may lead to feeding and print quality problems. In addition paper with excessive post-image curl may be difficult to handle or use in automatic-feed photocopiers. The curl side of the paper can be identified by a slight concave bowing from the outside edges of the paper stack towards the center of the top sheet. This curled side is always the side that should face away from the printer’s photoconductor. Having the curl side face away from the photoconductor helps the paper separate from the photoconductor surface during the printing process. Paper curl becomes more obvious after fusing of a print. If the curl of a printed page appears too excessive, it is likely that paper handling problems may occur during duplex printing. If this is the situation, open the paper tray and turn the paper over. Try printing again. If the problem is still not resolved, select a different paper for duplex printing, and reserve the “problem” paper for single-sided printing. Besides paper handling problems, excessive curl may also result in blurred print and similar print quality problems. The HP standard for in-ream paper curl is no more than 0.2 inches (5 mm) on any part of the paper, with 0.1 inches (3 mm) the optimal value. Finish (Texture) Finish, or texture, is the degree to which the surface is free of irregularities (or the smoothness or roughness of the paper). Using paper that meets HP specifications for surface texture is critical to the operation of D640 printers. The degree of surface texture is determined by the fiber composition of the paper, fillers which may have been added to the paper mixture, and the number of passes through the calendar stacks. Common paper textures included cockleshell, linen and laid. D-6 Using Paper, Media Selection Specifications and Guidelines

Using Paper Potential Problems

Some textures improve paper feeding while others hinder the feed operation. Too smooth or too rough paper can cause a variety of problems in D640 printers. Table D-2 Finish (texture) potential problems Problems Too Smooth Too Rough • misfeeds • misfeeds Feeding • multi-feeds • poor toner adhesion • poor toner adhesion • washout will show up (loose • light and dark transitions (toner Print toner particles from a previ- migrates to the valleys of the paper Quality ously printed page) surface, but not the peaks) • background toner scatter • printed characters may have broken edges none • registration roller Premature • paper path rollers Wear • fuser • paper path guides Felt Side vs.Wire Side The way paper is manufactured results in two-sided paper properties. This, along with other process variations, may make one side of the paper the preferred side to print on. The “top” side of the paper sheet as it is formed is known as the felt side, and the “bottom” is known as the wire side. Most manufacturers indicate the preferred printing side on the package. Moisture Content Note Moisture content is the most critical factor in paper performance in D640 printers. The moisture content of most paper at the time of manufacture is about 4-6% of volume by weight. This percentage can be altered as a result of environmental conditions during converting processes, shipping, storage, and printing. Storage, especially over long periods, can greatly influence moisture content. Because of the hygroscopic properties of paper, unless proper humidity and temperature are maintained, the paper will lose or gain moisture. Using Paper D-7, Media Selection Specifications and Guidelines The environmental conditions required to maintain the proper moisture content is 68°F to 75°F (20°C to 24°C) with a relative humidity of 45% to 55%. Table D-3 Moisture content potential problems • Paper shrinks unevenly during fusing, causing print quality problems Too Moist • Overall paper curl increases (increases post-image curl, causes poor toner adhesion, feed and print quality problems) • Excess static (causes multi-feeds and paper jams) Too Dry • Surface electrical resistivity (causes streaking and smudging of loose toner particles) The HP standard for moisture content is 4.7% ± 1% by weight. Although a paper may have the proper moisture content at the time of manufacture, exposure to temperature and humidity extremes may alter the percentage.

Fusing Compatibility

Media that does not meet HP specifications may: • Discolor • Melt • Scorch • Offset • Release hazardous emissions • Have poor toner adhesion • Break down in other ways • Possibly damage the printer All media used in D640 printers must have the ability to withstand the fusing temperature of 392°C/200°C for 0.1 second, without experiencing any problems. Inspect the rollers for colored ink build-up from pre-printed logos or letterhead and for toner buildup or spots. Inspect printed output for repetitive defects and smearing. If necessary, contact your forms vendor to ensure paper’s fusing compatibility with D640 printers. D-8 Using Paper, Understanding Paper Ream Labels

Using Paper Understanding Paper Ream Labels

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

General Guidelines

Some general guidelines to follow when selecting media are summarized on the following pages. Use conventional white xerographic paper for most printing. The paper should be of high quality, free of cuts, tears, grease spots, loose particles, dust, wrinkles, voids, and curled or bent edges. Xerographic papers, also called photocopy or xerocopy papers, are usually made from chemical wood pulp and are characterized by a smooth surface, controlled electrical properties, heat stability, and cleanliness. These characteristics ensure good image transfer, fusing without excessive curl, and reliable printer operation. Some applications may require a paper having a more prestigious look or feel. Bond papers generally have a watermark and often use cotton fiber. These papers tend to have a rougher surface and their properties may not be controlled like xerographic papers. However, your D640 printer will print satisfactorily on many of these bond papers. Also, some paper manufacturers are now making laser grade bond papers which have properties compatible with laser quality printing. One of the most important things you can do to ensure the best possible performance from your D640 printer is to select a quality paper. Table D-4, “Recommended paper specifications”, summarizes the specifications of a paper that will give you the best performance. Using Paper D-9, General Guidelines Note It is possible that paper could meet all of the general specifications listed in this table and still not print satisfactorily because of the printing environment or other variables over which Hewlett-Packard has no control.

Recommended Paper Specification Summary

Table D-4 Recommended paper specifications Parameter Specification Paper Weight 17 to 24 pound (64 to 90 g/m ) for printer and HCI; printer supports up to 36 pound (135 g/m2) Paper Grade No. 1 or No. 4 electrophotographic Paper Direction Long grain (parallel to the long dimension)Short grain (ideal for letter/A4 size paper) Furnish Fiber composition: 100% chemical wool pulp and /or cotton fiber Ash Content Not to exceed 10% Moisture Content 4.7 ± 1% by weight 100 to 200 Sheffield units Smoothness Front side: 30 ± 12 Sec Back side: 23 ± 10 Sec 0.45 to 0.65 Friction Coefficient 0.55 to 0.15 (dynamic) 0.60 ± 0.15 static 10 12 Surface Resistivity 10 to 10 Ohms Caliper 97± 3 em Finishing Cut sheet to within ±0.03 in (±0.8mm) of nominal, ±0.2° square Cut Edge Conditions Rotary precision cut Packaging Polylaminated moisture-proof ream wrap D-10 Using Paper, General Guidelines

Using Paper

Table D-4 Recommended paper specifications Parameter Specification Stiffness Printing direction: 90 ± 25 (Clark Method) Cross direction: 40 ±15 Fusing Compatibility Must not scorch, melt, offset, or release hazardous emissions when heated to 392° F (200°C) Opacity 84% ± 3% Wax Pick 12 minimum (Dennison) Grain Letter / A4 is best with short grainFor all other sizes, use long grain

Pre-printed Forms and Letterhead

To avoid multiple feeding and jamming problems when using pre-printed forms, embossed paper, and letterhead, observe the following guidelines: • Do not use low-temperature inks (the kind used with some types of thermography). • Use forms and letterhead printed by offset lithography or engraving. • Forms must be printed with heat-resistant inks that will not melt, vaporize, or release hazardous emissions when heated to 392°F (200°C) for 0.1 second. Typically, oxidation- set or oil-based inks meet this requirement. • If oxidation-cured inks are used, the use of oxidation retardants should be minimized. • When the form is pre-printed, be careful not to change the moisture content of the paper, or use materials that change the paper’s electrical or handling properties. Forms should be sealed in moisture-proof wrap to prevent moisture changes during storage. • Pre-printed forms should not be processed with a finish or coated at the end of their production. • Do not use heavily embossed or raised letterhead papers. • Avoid papers with heavily textured surfaces. • Avoid using a band of ink on the leading edge of the paper. • Water additives must not be used, as they change the conductivity of the paper. The effect of the electrical charge applied to the paper during the printing process may be altered. • Following offset printing, the printed pages should be allowed to dry for one to two weeks in an atmosphere of 60°F to 80°F (16°C to 27°C) with a relative humidity of 35% to 50%. Using Paper D-11, General Guidelines

Adhesive Labels

For the purposes of this specification, a label is defined as paper with a pressure-sensitive adhesive backing. Label stock includes the top or face sheet, the adhesive, and the liner or carrier sheet, also referred to as the backing. Note the following points about label stock: • Top or face sheets: The top sheet, which is the printing surface, is usually composed of xerographic paper. Label top sheets must provide good toner adhesion. • Carrier sheets: The carrier sheet must be compatible with the temperatures and pressure of the fusing process, and must be coated for easy release of the top sheet. • Adhesives: The adhesive must be stable at the 392°F (200°C) temperatures encountered in the printer's fusing process, and must not produce emissions that exceed exposure levels or threshold limits established by OSHA and other safety agencies. Adhesives must not come in direct contact with any part of the printer. No adhesive should be pressed out of the edges or between die-cuts (the cuts between individual labels). • Label arrangement: Labels should be arranged on the carrier sheet so that any exposed spaces run lengthwise down the sheet (See Table D-5, “Label specifications”.) Using label stock with spaces between the horizontal rows of labels can often result in labels peeling off during printing, causing serious jamming and possible printer damage. Labels may be specially manufactured to leave a margin around the outside edges that correspond to the outer margins of the printable area. If this special arrangement is to be used, DO NOT REMOVE the excess top sheet material from the carrier sheet. Figure D-3 Adhesive Label arrangements D-12 Using Paper, General Guidelines

Using Paper

Note It is possible that labels could meet all of the general specifications listed in "Adhesive Label arrangements" and still not print satisfactorily because of the printing environment or other variables over which Hewlett-Packard has no control. Table D-5 Label specifications Must not be on any external surfaces of the label before, during or after Adhesive printing.Label construction and die-cutting must not allow labels to peel off during transport, printing, or fusing. Basis Weight 32 to 34 pounds (120 to 128 g/m 2). Curl In-ream: flat within 0.2 in. (5 mm). Finishing Cut sheet within 0.031 in. (0.79 mm) of nominal and within 0.2° of square. All adhesives, carrier sheets, top sheets, and other materials used in Fusing label construction must be compatible with the heat and pressure of the Compatibility fusing process. Materials must not discolor, melt, offset, or release hazardous emissions when heated to 392°F (200°C). Packaging Moisture proof wrap to preserve properties. Shelf Life One year, minimum, stored at 72°F (22°C) and 50% R.H. Refer to Purchasing in the next section for ordering HP labels. Note The following actions can cause labels to peel off, possibly damaging the inside of your printer: printing on labels while the printer is in duplex mode or removing individual labels from the carrier sheet, then printing on the remaining labels. Note Hewlett-Packard does not recommend removing any labels from the carrier sheet and then printing on the remaining labels. If labels must be removed, remove them from the bottom of the carrier sheet, continuing toward the top. Note Overhead transparencies used in D640 printers must be able to withstand the 392°F (200°C) temperature encountered in the printer's fusing process. Specifications for overhead transparencies are summarized in Table D-6, “Overhead transparency specifications summary”. Using Paper D-13, General Guidelines Refer to Purchasing in the next section for ordering HP transparencies. Table D-6 Overhead transparency specifications summary Basis Weight 45 to 60 pound (170 to 225 g/m ) Cutting Angle 90°plus or minus 0.2° Finishing Plus or minus 0.03 in. (plus or minus 0.8 mm) Fusing All materials of the overhead transparency must be compatible with the heat and pressure of the fusing process. Materials must not discolor, melt, offset material, Compatibility or release hazardous emissions when heated to 392°F (200°C). Recycled Paper Recycled paper is a combination of waste paper, pre-consumer waste, and post-consumer waste. Printed waste paper is usually washed to remove most of the inks and other contaminants. A recycled sheet of paper may contain dark specks or appear gray or dirty. You should choose a recycled paper that meets the same specifications (except perhaps brightness) as standard paper, and has an appearance suitable for your needs. Hewlett-Packard recommends that the recycled paper contain no more than 5% groundwood. Note Depending on the quality of recycled paper, you may experience a higher jam rate and reduced consumable life compared to equivalent quality non-recycled paper. Archival Paper Paper used for archiving must meet the same specifications as standard paper, however, the pH should be no less than 7.0. Some archival demands are more stringent than others, requiring the degree of alkalinity and chemical stability to be specified. Toner is chemically stable and should last as long as the paper does. Toner can be degraded by petroleum based solvents or plasticizers, such as those found in vinyl folders. Avoid folding archival documents across printed areas or handling them roughly. Discuss archival requirements with your paper supplier. Colored Paper Colored paper can be used in D640 printers as long as the standard paper specifications are met. D-14 Using Paper, General Guidelines

Using Paper

Paper with Cutouts or Perforations Hewlett-Packard does not recommend using paper with cutouts or perforations because they often cause paper handling problems and may cause printer damage. A cutout is defined as any portion of the paper that has been removed, including binder holes, notches, square cuts, etc. Paper with internal perforations may cause misfeeds and paper jams. If you must use papers with internal perforations or cutouts, take care to conform to the following: • Cutouts and perforations should be punched from the side to be printed on, so that edge trimmings will not scratch the photosensitive belt. • Do not print at a cutout location, or closer than 1/8 inch (3.5 mm) to the edge of a cutout, to prevent toner from contaminating the inside of the printer. • Cutouts and perforations should be cut clean (without burrs), to avoid multiple feed, contamination problems, or paper jams. • Avoid perforations that run perpendicular to the paper path. When the printer transfers paper from one set of rollers to the next, a perforation can cause the page to bend downward and miss the pickup point on the next roller. Chemically Treated Paper Coatings such as lacquers, polymers, laminations or other chemicals protect the paper but can cause problems in the fuser and transfer areas of D640 printers. The surface resistivity and moisture content can be greatly altered, resulting in print quality problems. Hard surfaces coatings increase wear on the rollers and paper guides. All chemically treated paper must meet HP specifications for fusing compatibility. Synthetic Paper Synthetic papers (those manufactured from man-made fibers) do not perform as well as bond papers in any printer, especially D640 printers. Each type has its own problems which result in poor feed and print quality performances. All synthetic papers must follow HP specifications, especially for caliper and fusing compatibility. Be cautious about heat-generated fumes which may be dangerous to breathe. Coated Paper Do not use papers where a coating has been added after the paper is produced. Most coated paper does not meet specifications for fusing compatibility, as well as all other specifications for D640 printers. Using Paper D-15, Purchasing, Handling, and Storing

Other Special Media

Odd sizes Check minimum and maximum supported sizes in Figure 3-4, Paper Sizes quick refer- ence, on page 3-4. Carbonless Paper Carbonless paper (NCR) is not supported by D640 printer. Recycled Paper Choose recycled paper that meets HP specifications (except perhaps brightness) and that has an appearance suitable for your needs. HP recommends that recycled paper contained no more than 5% groundwood.

Things to Avoid

DO NOT attempt to print on any of the following: • Extremely shiny or glossy paper. • Very rough, textured, or embossed media. • Multipart forms or carbonless papers. • Media, media coatings, dyes, or inks that produce hazardous emissions or melt when exposed to a fusing temperature of 392°F (200°C). • Media that offsets or discolors. • Media with folds, staples, paper clips, etc. • Damaged, curled, wrinkled, or irregularly shaped media. • Letterhead paper produced using low temperature dyes or thermography. • Paper containing large amounts of clay or talc. • Media that have already been printed with a photo copier or a D640 printer. • Low quality recycled paper.

Purchasing, Handling, and Storing

The performance of D640 printers is dependent on the condition of the print media used. This section contains recommendations for purchasing, shipping, handling and storing media. Acceptable paper can be purchased from your local supply house. Ask your vendor to verify that the paper will work acceptably with a D640 printer. In the United States, overhead transparencies are supplied by Hewlett-Packard through HP SafetyNet (to order transparencies in Europe, contact your local HP sales office). To order from HP SafetyNet, call (800) 538-8787 and ask for the HP part number listed below. Each box contains 50 overhead transparencies. D-16 Using Paper, Purchasing, Handling, and Storing

Using Paper Purchasing Information

Transparency Size HP Part Number Letter - 8.5 x 11 in. (216 x 279 mm) 92296T A4 - 210 x 297 mm (8.26 x 11.69 in.) 92296U In the United States, Hewlett-Packard supplies labels through HP SafetyNet (to ordering labels in Europe, contact your local HP sales office). To order from HP SafetyNet, call (800) 538- 8787 and ask for the HP part number listed in Table D-7, “Hewlett - Packard laser printer label media”. Each box contains 100 sheets, 81/2 x 11 inch (216 x 280 mm), except where otherwise noted. Table D-7 Hewlett - Packard laser printer label media Label Size Number per HP Part Number (Height and Weight) sheet1x25/8 in (25 1/2 x 51 mm) 30 92296A 1 1/3 inx4(25 1/2 x 102 mm) 14 92296B1x4in (25 1/2 x 102 mm) 20 92296C2x4in (51 x 102 mm) 10 92296D 3 1/3 inx485 x 102 mm) 6 92296E 1/2 inx13/4 (13 x 45 mm) 80 92296F 2/3 inx37/16 (18 x 88 mm) 30 92296G 2 3/4 inx23/4 (70 x 70 mm) 9 92296H* 1 1/2 inx4(39 x 102 mm) 12 92296J* 8 1/2 x 11 in (215 x 280 mm) 1 92296K *Contains 75 sheets, 8 1/2 x 11 in. (216 x 280 mm).

Shipping

When print media are shipped through different environments, the entire stack of cartons on the shipping pallet should be plastic wrapped. When shipped across bodies of water, individual cartons should be wrapped, as well. Media should never be shipped in such a manner that they are damaged or bent along the edges. Using Paper D-17, Purchasing, Handling, and Storing

Storing

Adhere to the following guidelines when stacking and storing print media: • DO NOT store cartons of reams directly on the floor; cartons should be placed on a pallet or on shelves. • DO NOT store individual reams in such a manner that they will curl or warp along the edges. • Rewrap partially used reams of paper before storing. • DO NOT stack more than six cartons high. • Stack each carton squarely on top of the one underneath. • Stack each carton upright. • DO NOT place anything on top of paper, regardless of whether the paper is packaged or not. • Store envelopes in a protective box so the edges will not be damaged. • Keep stored media away from extremes in temperature and humidity. • DO NOT store printed documents in vinyl folders (which may contain plasticizers), or expose the documents to petroleum based solvents.

Environmental Considerations

Media should be protected from temperature and humidity extremes. D640 printers are designed to operate in a wide range of environmental conditions, but for best performance, media should be stored and used at 59°F to 95°F (15°C - 35°C), with a relative humidity of 40% to 60%. When media are used in an environment outside the ranges of temperature and humidity shown above, follow these guidelines: • DO NOT leave the media exposed to humidity or temperature extremes. Any extreme changes in the environment will cause the media to take on unwanted characteristics if left unwrapped or in the input tray of the printer. • Where humidity extremes occur, store paper in an airtight container, or seal it in plastic. • If there is a significant temperature difference between the media storage area and the printer’s operating environment, allow the media to adjust to the temperature in the printer’s operating environment before unwrapping. The greater the temperature difference and the greater the amount of media to equilibriate, the longer this time period should be. Allow one day for every 20°F (10°C) difference in temperature between storage environment and printing environment. Paper is affected by temperature and humidity variations during transport, storage, and use. When the atmosphere is moist, paper tends to have wavy edges; conversely, when the atmosphere is dry, paper tends to have wavy centers. D-18 Using Paper, Purchasing, Handling, and Storing

Using Paper

Acclimatizing paper to the “best performance conditions” described above minimizes these adverse affects, but exposure to temperature and humidity extremes will eventually make acclimatization impossible. In extreme conditions, the paper may become unfit for use. For optimum results, keep paper supplies in moisture-proof packaging and load only the amount that will be used soon.

Printer Normal Operating Environment

The specifications for the printer's operating environment are defined below. Observing these environmental guidelines helps ensure trouble-free printer operation.The temperature and humidity of the paper used with the printer should be in balance with the printer's environment. • Temperature 59°F to 95°F (15°C to 35°C) • Relative Humidity 20% to 80% • Altitude 0 to 7000 feet (0 to 2150 m) Total Operating Environment Figure D-4 is a map of the operating range of the printer, showing recommended maxima and minima for temperature and humidity. Operating the printer in the A,C, D, and E areas of Figure D-4 may result in lower-quality prints. 95°F (35°C) D 85°F (30°C) TemperatureABC65°F (18°C)

E

59°F (15°C) 20% Humidity 80% Figure D-4 Total operating environment Using Paper D-19, Troubleshooting

Troubleshooting

Paper problems are somewhat difficult to detect. A series of steps will help isolate paper- induced problems. The steps to follow are: • Is it a paper or a printer problem? • Isolate a paper path • Isolate a paper brand • Isolate a paper type • Evaluate user’s paper practices • Evaluate environmental conditions Is it a Paper or Printer Problem? When determining a printer failure, a distinction must be made between problems relating to the printer itself and those involving paper. Often a problem which first appears to be related to the printer is actually a matter of poor paper selection or handling. To determine is a problem is printer or paper-induced a few simple steps can be helpful: • Turn paper over in the tray to print on the reverse side. • Rotate sheets 180° (end to end) to feed with a different leading edge. If the symptoms cease, or change in some way, it can be assumed that the problems are paper induced. Isolate a Paper Path The physical properties and composition of a particular paper influence its motion along a printer’s main paper path. As a general rule, the straighter a paper path, the more forgiving it is of the paper’s physical characteristics. Try Using the Straightest Paper Path Some problems can be avoided by using the straightest paper path. Feed paper from tray1. This path is recommended for transparencies and heavy basis weight media.

Ltr Ltr Ltr

Figure D-5 D640 paper paths D-20 Using Paper, Troubleshooting

Using Paper

Determine if the Problem is Due to Duplexing The duplexing feature may have both paper feed problems and print quality problems as a result of printing on paper that has just made a pass through the printer (resulting in increased paper curl). This paper curl increases image dropout, and pickup and stacking problems. The second pass is made with paper which may no longer meet the specifications for moisture and curl. Dry paper may not hold static charges which affect print quality and stacking. Image mis- alignment front-to-back on a duplexed page may be caused by paper shrinkage. Isolate the Source From Which the Printer Jams Where was the paper being fed from? Possible sources include: • Tray1, Tray2, Tray3 (500 20 pound paper sheets each) • High Capacity Input Unit (3000 20 pound paper sheets) Where Does the Jam Occur? Check where paper stops when a jam occurs. Types of jams that can occur include: • Input paper jams • Internal paper path jams • Output jams Is the Printer is Experiencing Multi-feed Jams? The following are some possible causes in multi-feeds. • Paper may be too light or too thin. Check the basis weight and caliper. • Paper may be too smooth or too rough. Check the finish. • Paper may have too much curl. Measure paper curl and check moisture content. • Paper may have bad edge cuts or edge welds. Observe the cut edge condition. • The customer may be attempting to print embossed paper, pre-printed forms, or perforated paper which does not meet HP specifications. (See the following section,"Isolate a Paper Type", for details about the difficulties of embossed paper.) • Paper may be loaded incorrectly. Turn over the sheets in the paper tray to determine if in- ream curl is the cause of misfeeds. • Customer may be fanning paper before loading it into the paper tray. • Customer may be adding paper in small amounts. Do not add small amounts of paper or mix types of paper in the tray. • The printer or paper storage environment may be too humid or too dry. (As a result, paper may be too moist or too dry). Determine if this is the case and advise the customer. Using Paper D-21, Troubleshooting Is the Printer Experiencing Misfeeds? The following are some possible causes in misfeeds. • Paper may be too stiff. Check basis weight and measure caliper. • Paper may be too smooth or too rough. Check the finish. • Paper may be too heavy or too light. Check the basis weight. • The customer may be attempting to print embossed paper, pre-printed forms, or perforated paper which does not meet HP specifications. (See the following section, "Isolate a Paper Type", for details about the difficulties of embossed paper.) • Paper may be loaded incorrectly. Turn over the sheets in the paper tray to determine if in- ream curl is the cause of misfeeds. • Customer may be fanning paper before loading it into the paper tray. • The printer or paper storage environment may be too humid or too dry. (As a result, paper may be too moist or too dry). Determine if this is the case and advise the customer. Isolate Paper Brand If the printer jams with only one brand of paper: • If the paper ream being used appears to be old, open a fresh ream of the same paper and load it properly into the printer. If the problem is remedied, investigate storage and handling conditions. • Do not purchase more paper than you can use in a short time (3 months). Paper stored for longer periods may experience heat and moisture extremes which can damage it. Planning helps prevent damage to your paper supply. • If the problem persists, try switching paper brands. Isolate a Paper Type When paper jams and other problems occur frequently, it is often because special paper is causing the difficulty. Use only paper that conforms to all HP specifications, and always test paper before purchasing large quantities. If future problems occur, the cause may be easily isolated to storage or handling conditions. Some types of media that may cause problems are: • Pre-printed forms and special letterhead • Embossed paper • Perforated paper • Adhesive labels • Envelopes • Transparencies • Chemically treated paper D-22 Using Paper, Troubleshooting

Using Paper

• Synthetic paper • Coated paper • Other special media Refer to Table D-4, “Recommended paper specifications,” on page D-10 for a table of recommended media specifications. Printer Maintenance General cleanliness of the printer is the most important part of printer maintenance. Good maintenance improves the performance of any printer. Papers which create a lot of dust and debris in the printer require a more aggressive maintenance schedule. Areas which builds up paper dust heavily are: • pick-up rollers • paper guides Taking extra time to clean and inspect the paper path results in fewer paper jams and cleaner print. If problems continue after cleaning, inspect for wear or damage. Paper Stacking Consider the following guidelines when advising the customer about stacking paper: • Do not store cartons of reams directly on the floor; cartons should be placed on a pallet or on shelves. • Do not stack more than six cartons high. • Stack each carton squarely on top of the other. • Stack each carton upright. • Do not store individual reams in such a manner that they will curl or warp along the edges. • Do not place anything on top of paper, whether it is packaged or unpackaged. • Do not place paper close to heating or air conditioning vents or open windows.

Evaluate Environmental Conditions

Printing Environment Ideally, the printing environment should be at or near room temperature, and not too dry or too humid. Remember, paper is hygroscopic; it absorbs and loses moisture rapidly. Heat works with humidity to damage paper. Heat causes the moisture in paper to evaporate, while cold causes it to condense on the sheets. Heating systems and air conditioners remove most of the humidity from the room. As paper is opened and used, it loses moisture, causing streaks and smudging. Humid weather or water coolers can cause the humidity to increase in a room. As paper storage is opened and used it absorbs any excess moisture, causing light print and dropouts. Using Paper D-23, Troubleshooting Paper Storage Environment Paper storage and handling is as important as the paper-making process itself. Paper storage environment conditions directly affect the feed operation. Do not purchase more media than you can use in a short time (3 months). Paper stored for long periods may experience damage from heat and moisture extremes. Planning is important to prevent damage to a large supply of paper. Unconverted paper in sealed reams can remain stable for several months before use. Converted papers have more potential for environmental damage, especially if they are not wrapped in a moisture-proof barrier. Maintain paper in a storage environment of 59° to 95°F (15° to 35°C), with a relative humidity of 40% to 60%. • Paper should be stored at or near room temperature. • The air should not be too dry or too humid (due to hygroscopic properties of paper). • The best way to store an opened ream of paper is to re-wrap it tightly in its moisture-proof wrapping. If the printer environment is subject to extremes, unwrap only the amount of paper to be used during the day’s operation. D-24 Using Paper,

Printing Reports E Printing Reports

The D640 printer has built-in reports that can be printed as offline test prints. This appendix describes how to print these reports and gives a sample of each type of report.

The Printer Setup Report

The printer stores all configuration settings. The setup report show the printer’s current configuration options as well as page counts and code revision values. To print the Setup report: 1. At the Main Screen, press Test. SETUPS is highlighted. 2. Press Select. A two-page report is printed: Figure E-1 (1 of 2) lists all menu settings. Figure E-2 (2 of 2) lists information about the floppy and hard disk drives. Printing Reports E-1, The Printer Setup Report345678Figure E-1 Printer Setup Report Sample (1 of 2) E-2 Printing Reports, Setup Report, Page 1 Key

Printing Reports Setup Report, Page 1 Key

a This is the serial number for your printer. b This is the time of day the Setup Report was printed, shown in the upper left corner as a clock face, and in the lower right corner as text. c This section lists all of the current values for the Printing Menu settings. If you have installed an HCO, you will also see the outbin, joboffset, and HCI-alias settings. d This section lists all of the current values for the Configuration Menu settings. e This section lists all of the current values for the PCL Menu settings. f This section lists all of the current values for the Comms (Communications) Menu settings. g This section lists all of the current values for the Maintenance Menu settings. h This section lists all of the current values for the PapSize Menu settings. i This section lists information about the current state of the printer and some statistics about its operation. The Total page count is the number of pages printed since the last report was printed. Paper Height and Width are the physical dimensions of the paper in the current INTRAY. Print Width and Height are the dimensions of the image printed on the paper. Total RAM size is the amount of memory in the printer. Page RAM size is the amount of memory available to compose images. This space is used for fonts, graphics, and other information. Free RAM size is the amount of memory left over after page RAM is reserved. The last four lines of this section contain version numbers for printer hardware and software. In the event of problems, your service representative may ask for these version numbers to help troubleshoot the printer. Printing Reports E-3, Setup Report, Page 1 Key123Figure E-2 Printer Setup Report Sample (2 of 2) E-4 Printing Reports, Setup Report, Page 2 Key Printing Reports Setup Report, Page 2 Key a This is the time of day the Setup Report was printed, shown in the upper left corner as a clock face, and in the lower right corner as text. b This area shows the contents of any diskette inserted in the internal 3.5" disk drive (filesA). c This area shows the contents and details of the internal hard drive (filesC). Printing Reports E-5, The Maintenance Report

The Maintenance Report

The Maintenance report will show all the important maintenance events (such as jams, alarms, and errors) as well as consumable status. To print the Maintenance report: 1. At the Main Screen, press Test. SETUPS is highlighted. 2. Press N to highlight MAINT. 3. Press Select. Figure E-3 shows the Engine Status, Maintenance Counters, and the Event Log. The engine status is used only by a service representative.

Maintenance Report Key

a This is the serial number for your printer. b This is the time of day the Maintenance Report was printed, shown in the upper left corner as a clock face. It is also printed in the lower right corner as text (not visible in this illustration). c This section lists all of the current values for the printer engine. d This section lists all of the current values of the counters tracking consumable lifetimes. CURRENT indicates the cumulative use for each consumable since it was replaced. MAXIMUM indicates the recommended maximum usage for each consumable. REPLACE indicates the point at which the consumable should be replaced. The Control Panel indicates when a particular consumable has reached this point. USAGE indicates the percentage of use for each consumable (except toner). When this value reaches 100%, the printer displays an end-of-life message to indicate the consumable should be changed. e This section lists errors that have occurred in the D640 since the last Maintenance report was printed. E-6 Printing Reports, Maintenance Report Key

Printing Reports

Figure E-3 Printer Maintenance Report Sample Printing Reports E-7, The Typeface Report

The Typeface Report

The D640 comes with a number of fonts (typefaces). The typefaces available are very close to those found on an HP LaserJet 4si. To get a list of these typefaces, follow this procedure: 1. At the Main Screen, press Test. SETUPS is highlighted. 2. Press N to highlight FONTS. 3. Press Select. Figure E-4 provides examples of the installed typefaces resident in the printer. If you have selected a virtual font cartridge, you will see the message "not installed" instead of a font sample. This is because the font image is "not installed" in memory until it is selected by your print job. Once it has been selected, you can reprint this report and see a sample of the font.

Typeface Report Key

a This is the time of day the Typeface Report was printed, shown in the upper left corner as a clock face. It is also printed in the lower right corner as text. b This section lists all of the installed typefaces. E-8 Printing Reports, Typeface Report Key

Printing Reports

Figure E-4 Typeface Report Sample Printing Reports E-9, The Symbol Set Table Report

The Symbol Set Table Report

The printer has individual symbol sets for each typeface. This report shows the symbol set and codes for the symbol set specified in the PCL menu setting. The printer prints a page for each font in the printer. To print the Symbol Set Table report: 1. At the Main Screen, press Test. SETUPS is highlighted. 2. Press N to highlight TABLE. 3. Press Select. A one page report is printed: Figure E-5 lists the font name, code for the font, pitch, weight, and type code.

Symbol Set Table Report Key

a This is the time of day the Symbol Set Table Report was printed, shown in the upper left corner as a clock face. It is also printed in the lower right corner as text. E-10 Printing Reports, Symbol Set Table Report Key

Printing Reports

Figure E-5 Symbol Set Table Report Sample Printing Reports E-11, The Printer Menu Settings Report

The Printer Menu Settings Report

The printer can print a report showing the complete menu tree. To print the Menu Settings report: 1. At the Main Screen, press Test. SETUPS is highlighted. 2. Press N to highlight MENUS. 3. Press Select. Figure E-6 identifies all Printing Menu, Configuration Menu, PCL Menu, Communications Menu, Maintenance Menu, and Paper Size Menu settings. In these examples of the Printer Menu Setting Report Pages, the default factory setting is indicated by the "=" sign in front of the setting option.

Printer Menu Settings Report Key

a This is the time of day the Printer Menu Setting Report was printed, shown in the upper left corner as a clock face. It is also printed in the lower right corner as text. E-12 Printing Reports, Printer Menu Settings Report Key

Printing Reports

Figure E-6 Printer Menus Report Sample (Sheet 1 of 3) Printing Reports E-13, Printer Menu Settings Report Key Figure E-7 Printer Menus Report Sample (Sheet 2 of 3) E-14 Printing Reports, Printer Menu Settings Report Key

Printing Reports

Figure E-8 Printer Menus Report Sample (Sheet 3 of 3) Printing Reports E-15, The Ripple Test Print

The Ripple Test Print

The printer provides a test print ripple pattern that is useful in checking print quality and paper feeding. The test print pattern uses the font and point size specified in the PCL menu. To print a test print ripple pattern: 1. At the Main Screen, press Test. SETUPS is highlighted. 2. Press N to TESTPRINT. TESTPRINT is highlighted. 3. Press Select. Note TESTPRINT will print several pages. You can change the number of pages printed by altering the testpages configuration in the Maintenance menu (See “Maintenance Menu Settings” on page 2-24). Figure E-9 shows the ripple test pattern. The pattern allows visual observations of print quality.

Troubleshooting with the Ripple Test Pattern

The ripple test pattern can help determine if the printer is operating at optimum performance or if it needs maintenance. 1. Look at the test pattern and other print jobs that indicate print quality problems. 2. Go to “Maintaining Print Quality” on page 6-1 and follow the instructions for comparing your observations to the supplied problem samples. 3. Identify the problem with the sample and perform the maintenance as described. E-16 Printing Reports, The Ripple Test Print

Printing Reports

Figure E-9 Printer Ripple Test Pattern Sample Printing Reports E-17,

Warranty and Support F Warranty and Support Where To Call For Help

We have established phone numbers for you to call and receive help should any questions or problems arise during the installation of the D640 printer or any of its accessories. The numbers listed are available during normal business hours of 8:00 AM to 5:00 PM. This phone assistance is available free of charge (except phone tolls) during the first year after shipment of your printer. You may call as often as necessary for assistance with the following items: • Installation • Configuration • Daily use, such as clearing paper jams or installing consumables • Questions about the manuals Prior to calling you should have your printer’s serial number available. This can be found on a label located on the upper right corner of the printer when the printers front door is open. It will look like "JP20000149". In addition, have your question ready and be near the printer if necessary. After the first year you may continue to use this service for a per-call fee, which will be specified when you call. Note Please call your local HP Support Organization for all service related issues and for all locations that are not directly listed. Refer to the next page for a list of regional Support Organization telephone numbers.

For installation and general printer questions, call:

• The toll-free number in the US and Canada is: 1-888-223-6774 • The alternate number for the US, Canada, and for English speaking callers is: 1-208-422-9102 • In Europe, use the numbers in Table F-1, “European installation support” to reach HP’s European support center in Amsterdam. Warranty and Support F-1, Where To Call For Help Table F-1 European installation support Austria 0660 6386 Netherlands 020 6068751 Belgium (Dutch) 02 626 8806 Norway 22 11 6299 Belgium (French) 02 626 8807 Portugal 01 441 7199 Finland 0203 47288 Spain 902 321 123 France 04 50 43 9853 Sweden 08 619 2170 Germany 0180 5 25 81 43 Switzerland 0848 80 11 11 Ireland 01 662 5525 UK 0171 512 5202 Italy 02 26410350

For hardware problems, call:

• In the US and Canada: 1-800-633-3600 • In Europe: • 31-20-682-26-28 (English) • 31-20-681-78-10 (German) • 31-20-681-77-50 (French) For the rest of the world, use the numbers in Table F-2, “International hardware support”. F-2 Warranty and Support,

Where To Call For Help Warranty and Support Table F-2 International hardware support Area Address Telephone

Canada Hewlett-Packard Ltd. 5150 Spectrum Way, Mississauga, Ontario, L4W 5GI 905-206-4725 Hewlett-Packard Ltd. 101, 17971-106A Avenue, Edmonton, Alberta T5S 1V8 403-425-4725 Hewlett-Packard Ltd. 17500 Trans Canada Highway, South Service Road, 514-697-4232 Kirkland, Quebec H9J 2X8 Latin America Hewlett-Packard Prolongacion Reforma 700, Lomas de Santa Fe, 01210 525-258-4077 de Mexico Mexico, D.F. Hewlett-Packard Montaneses 2140/50/60, 1428 Buenos Aires, Argentina 54-1-787-7100 Argentina S.A. Edisa R. Aruana, 125-Tambore, 06460-010-Barueri-Sao 55-11-726-4700 Hewlett-Packard S.A. Paulo, Brazil Australia and New Zealand Hewlett-Packard Ltd. 31-41 Joseph Street, Blackburn, Victoria 3130, Australia 61-3-272-2895 Hewlett-Packard 186-190 Willis Street, P.O. Box 9443, Wellington, New 64-4-802-6800 (NZ) Ltd. Zealand Japan Hewlett-Packard 9-1 Takakura-cho, Hachioji-shi, Tokyo 192 81-426-60-2111 Japan, Ltd. Hewlett-Packard Forum honjo 2F, 2-4-1 Honjo, Matsumoto-shi, 81-263-39-2454 Japan, Ltd. Nagano 390 Hewlett-Packard 6-6 Hosojima-cho, Hamamatsu-shi, Shizuoka 435 81-53-466-6231 Japan, Ltd.

Warranty and Support F-3

,

Where To Call For Help Table F-2 International hardware support Area Address Telephone

Europe Hewlett-Packard GmbH Lieblgasse 1, A-1200 Vienna, Austria 43-1-25000-555 Hewlett-Packard A/S Kongevejen 25, DK-3460 Birkeroed, Denmark 45-99-10-00 Hewlett-Packard Oy, Tekniset palvelut, Piispankalliontie 17, 02200 Espoo, 358-9-88721 Finland Hewlett-Packard GmbH Kunden-Informations-Zentrum, Berliner Strasse 111, 0180-5-32-62- D-40880 Ratingen, Germany 99 Hewlett-Packard Via G.di Vittorio, 9, 1-20063 Cernusco S/N (MI), Italy 39-2-92124341 Italiana, S.p.A. Hewlett-Packard B.V. Startbaan 16, 1180 AR Amstelveen, The Netherlands 31-20-5476432 Hewlett-Packard Postboks 60, Skoeyen, 0212 Oslo, Norway 47-22-73-59-05 Norge AS Hewlett-Packard A1. Jerozolimskie 181, 02-222 Warszawa, Polska 48-22-608-7700 Polska sp.z 0.0. Hewlett-Packard Edificio Escritorios Parque Oceano, 5 Pisco-F, 351-1-482-85- Portugal, S.A. Sto Amaro de Oeiras, 2780 Oeiras, Lisboa, Spain 00 Hewlett-Packard Ctra. N-VI, KM. 16,5000, 28230 Las Rozas, Madrid, 34-1-631-16-00 Espanola, S.A. Spain Hewlett-Packard Avda. Diagonal, 605, 08028 Barcelona, Spain 34-3-401-91-00 Hewlett-Packard In der Luberzen 29, 8902 Urdorf/Zurich, Switzerland 01-735-71-11 (Schweiz) AG Hewlett Packard 39, Rue de Veyrot, 1217 Meyrin 1, Switzerland 022-780-44-46 (Suisse) S.A. Hewlett-Packard Amen Corner, Cain Road, Bracknell, Berks RG12 1HN, 1344-360000 England

F-4 Warranty and Support

,

Where To Call For Help Warranty and Support Table F-2 International hardware support Area Address Telephone

India and Far East Area China 5-6/F, West Wing Office, China World Trade Centre, 86-10- Hewlett-Packard Co., No. 1 Jian Guo Men Wai Avenue, Beijing, 100004, 65053888 Ltd. People’s Republic of China Hewlett-Packard 17-21/F Shell Tower, Time Square, 1 Matheson Street, 852-2599-7090 Causeway Bay, Hong Kong Hewlett-Packard India, Paharpur Business Center, 21 Nehru Place, New Delhi 91-11-6472311- Ltd. 110 019, India 2328-2329- P.T. Hewlett-Packard Servisindo Gedung Berca, Jalan Abdul Muis 62, Jakarta 62-21-351-8788 10160, Indonesia Hewlett-Packard Korea 25-12, Yoido-dong, Youngdeungpo-gu, Seoul 150-010, 82-2-769-0114 Korea Hewlett-Packard Ground Floor Wisma Cyclecarri, 288 Jalan Raja Laut, 02-03-298-6555 50350 Kuala Lumpur, Malaysia Phillipines 9th Floor, Rufine Pacific Towers, 6784 Ayala Avenue, 632-894-1451 Corporation Makati City, Metro Manila 1229, Phillipines Hewlett-Packard 450 Alexandra Road, Singapore 119960 65-275-3888 Singapore Pte Ltd. Hewlett-Packard 8th Floor, HP Building, 337 Fu Hsing North Road, 886-2-712-0404 Taiwan Ltd. Taipei, Taiwan Hewlett-Packard Ltd. 23-25/F Vibulthani Tower II, 3199 Rama IV Road, 662-661-3900- Klongtan, Klong Toey, Bangkok 10110, Thailand 34 Hewlett-Packard Tecasin Business Centre, 243-243B Hoang Van Thu, 84-8-844-3441 Vietnam Unit G10-12, Tan Binh District, Vietnam

Warranty and Support F-5

, Warranty

Warranty HP Maintenance Agreements

Hewlett-Packard has several types of maintenance agreements that meets a wide range of support needs. On-Site Service Agreements To provide you with the support level best suited to your system usage and support budget, HP has on-site service agreements with two response times: Priority On-Site Service is designed for production-critical applications, giving you four-hour service response to your site for calls made during normal HP business hours. Next Day On-Site Service provides on-site support by the next working day following your service request. Extended coverage hours and extended travel beyond HP designated service zones are available for additional charges on most on-site service agreements.

HP5000 Model D640 Warranty

This warranty entitles you to standard warranty services for your HP5000 Model D640 printer and is available from HP worldwide. However, there may be local variations in the level of warranty service. You should contact the local HP Service Center to check for the applicable local warranty in your country or province. 90 Day On-Site Limited Warranty Hewlett-Packard warrants the HP5000 Model D640 printer and accessories against defects in materials and workmanship for a period of 90 days from purchase by the end user. During the warranty period, HP will, at its option, either repair or replace products which prove to be defective. The warranty period begins on either the date of delivery, or, where the purchase price includes installation by Hewlett-Packard, on the date of installation. To have your HP5000 Model D640 printer serviced by HP, contact the closest HP Service Center. Exclusions The warranty on your HP5000 Model D640 printer and accessories shall not apply to defects resulting from: • Improper or inadequate maintenance by customer. • Customer supplied software or interfacing. • Unauthorized modification or misuse. • Operation outside of the environmental specifications for the product. • Operation of non-supported printing media. • Duty cycle abuse (see note below) F-6 Warranty and Support, Warranty

Warranty and Support

• Operating the printer from a mechanical switch box without a designated surge protector. • Improper site preparation and maintenance. • Failure to perform key operator maintenance, as specified in the D640 User Manual. • Use of non-HP consumables (see note below), memory boards, interface boards, or adapters. Note The use of non-HP consumable supplies alone does not affect either your warranty or any maintenance contract you may have purchased. However, if an HP 5000 D640 printer failure or damage is found to be to be attributable directly to the use of a non-HP consumable, HP will not repair the printer free-of-charge. In this case, standard time and materials charges will be applied to service your printer for that particular failure or damage Operation of the printer beyond the limit of its duty cycle (printing greater than the equivalent of 300,000 single-sided pages per month) shall be deemed printer abuse and all repairs thereaf- ter will be billed on a time and materials basis. If you are using a mechanical switchbox, ensure that it is equipped with a surge protector. Damage to your printer could occur from the use of unprotected mechanical switch boxes. Limitations The warranty set forth above is exclusive and no other warrants, whether written or oral, is expressed or implied. Hewlett-Packard specifically disclaims the implied warranties of merchantability and fitness for a particular purpose. Service During The Warranty Period If your hardware should fail during the warranty period, contact an authorized HP dealer or your local Customer Service Center. Service After The Warranty Period If your hardware should fail after the warranty period, contact an authorized HP dealer or your local Customer Service Center. If you have an HP Maintenance Agreement, request service under your agreement. Warranty and Support F-7,

Index A configuring

for LaserJet compatibility 6-24 AC input power connector 1-15 paper size 2-26 accessories, printer 1-2, C-7 parallel interface B-4 adding, developer 4-12 serial interface 2-23, B-1 to B-3 adjusting connector paper guides 3-3, 3-4, 3-8 HCI 1-15 paper path alignment 6-11 to 6-22 HCO 1-15 alignment parallel interface B-1 duplex 6-19 serial interface B-1 measuring 6-15 consumables paper path 6-11 developer 4-9 printing alignment sheets 6-12 drum kit 4-18 setting values 6-20 fuser kit 4-29 arrows, continuation 2-8 HCI pick roller kit 4-42 introduction to 4-1

C list of 4-3

managing 6-6 call engineer, messages A-8 ordering 4-2 caution messages iv overview 4-2 checking pick roller kit 4-33 paper 2-5 replacement cycle 4-2 printer status 2-3 replacing 1-2 cleaning toner 4-4 duplex area 5-6 tracking 1-2 LED array area 5-10 continuation arrows 2-8 paper feed area 5-4 control panel 1-7 paper input trays 5-4 display brightness 2-2 periodic 5-5 to 5-12 features 2-2 precharger area 5-3 function buttons 2-2 printer exterior 5-5 introduction 2-1 required tools 5-1 navigating 2-7 reversing unit area 5-5 Custom menu 2-9 toner hopper area 5-2 custom paper 1-3, 2-27, 3-10 transfer assembly 5-6 custom paper tray 3-8 to 3-15 transfer assembly guide 5-9 specifications C-12 weekly 5-1 to 5-5 cleaning roller 1-11 D replacing 4-7 clearing, paper jams 3-22 to 3-49 decurler lever 1-11 See also paper jams 5-4 developer 1-13, 6-9 Comms menu 2-21 adding 4-12 compatibility replacing 4-9 LaserJet 1-1, 1-4, 6-24 developer collector bottle 1-13 Configuration menu 2-14 installing 4-16 developer fill lid 4-14 developer kit 4-3 Index-1, developer purge bottle 4-16 H display brightness 1-18, 2-2 documentation holder 1-15 hard disk 1-4 drum 1-11, 6-9 HCI 1-3, 1-16 installing 4-24 capacity 1-16 removing 4-21 connector 1-15 unpacking 4-23 dimensions chart C-8, C-11 drum kit 4-3, 4-18 door 1-16 replacing 4-18 electrical specifications C-9 duplex loading 3-16 alignment 6-19 paper jams 3-32 jams 3-38 paper shelf lowering button 1-16 printing 1-1, 1-2 release handle 1-16 printing edge-to-edge 6-23 service area C-8 duplex area, cleaning 5-6 service area requirements C-11 specifications C-7

E weight C-8, C-11

HCO 1-17, C-11 economode 2-17, 6-7 acoustics C-14 edge-to-edge printing 6-23 capacity 1-17 ejection unit 1-7, 1-15, 3-43 connector 1-15 Energy Star compliance 1-4, C-15 electrical C-11 error messages 3-49, A-7 heat production C-11 operating humidity C-12

F operating temperature C-12

paper capacity C-10 floppy disk drive 1-9 paper handling C-10 font cartridges. See virtual font cartridges paper jams 3-45 fonts, 4si compatibility 6-26 paper sizes C-10 forms, printing 1-1, D-11 power consumption C-11 function buttons 2-2, 2-6 processing speed C-10 fuser 1-11, 6-10, D-1 separating from printer 3-48 installing 4-31 specifications C-10 paper jams 3-36 high-capacity input. See HCI removing 4-30 high-capacity output. See HCO fuser kit 4-3 replacing 4-29 fuser locking knob 1-11 Index-2,

I managing, consumables 6-6

measuring, alignment 6-15 input capacity 1-1, C-7 media, selection D-3 installing memory, printer 1-1, C-2, C-7 developer collector bottle 4-16 menus drum 4-24 Comms 2-21 fuser 4-31 Configuration 2-14 paper trays 3-2 Custom 2-9 pick rollers 4-47 Maintenance 2-24 transfer assembly 4-27 PapSize 2-26 interrupting, printing 3-21 PCL 2-19 Printing 2-11

J Test 2-28

messages jams. See paper jams call engineer A-8

L caution iverror A-7

labels paper jams A-5 adhesive D-12 status A-3 arrangement D-12 warning iv, A-4 carrier sheet D-12 misfeeds, causes of D-5 die-cuts D-12 printing in duplex mode D-13 O size D-17 optional accessories, specifications C-7 specifications D-13 ordering laser standards C-16 consumables 4-2 LaserJet output tray 1-7 compatibility 1-1, 1-4, 6-24 ozone filter 1-15, 6-11 LCD display 1-3 replacing 4-17 See also control panel LED array area, cleaning 5-10 P loading, paper 3-16 locking, paper trays 3-18 paper checking 2-5

M guidelines for use 3-16

HCO capacity C-10 Main Screen 2-3, 3-10, 3-12 loading 3-16 maintenance orientation in trays 3-17 agreement F-6 selection D-3 introduction 5-1 size C-2 periodic cleaning 5-5 sizes 2-5, 2-6 print quality 6-1 specifications D-1 to D-24 weekly cleaning 5-1 stacker capacity C-2 Maintenance menu 2-24 tray capacity C-2 Maintenance report E-6 Index-3, paper feed area pick rollers cleaning 5-4 HCI 4-3 paper guides installing 4-47 adjusting 3-3, 3-4, 3-8 printer 4-3, 4-33 custom 3-8 replacing 4-33, 4-42 paper indicators 1-7 PostScript 1-3, C-12 paper input trays, cleaning 5-4 power cord 1-17 paper jams power source, disconnecting v clearing 3-22 to 3-49 power switch, main 1-7, 1-18 in duplex unit 3-38 powering on, printer 1-18 in feed path 3-26 Powersave indicator 2-3 in fuser unit 3-36 precharger area, cleaning 5-3 in HCI 3-32 print media D-1 in HCO 3-45 print quality 6-23 in reversing unit 3-40 degraded 6-23 messages A-5 maintaining 6-1 paper path 2-5 problems 6-2 adjusting alignment 6-11 to 6-22 troubleshooting 6-1, 6-4 paper side exit 1-15 printer paper size accessories 1-2 configuring 2-26 dimensions C-3, C-4 setting custom 3-10 fonts 6-26, C-2 setting standard 3-7 hard disk 1-4 table 2-6 heat production C-5 paper trays 6-24 interfaces C-2 adjusting guides 3-3 memory 1-1, C-2, C-7 default 6-25 orientation 1-5 installing 3-2 physical dimensions C-4 locking 3-18 pick rollers 4-3, 4-33 removing 3-2 power consumption C-5 paper, custom 1-3 powering on 1-18 PapSize menu 2-26 resetting A-1 parallel interface resolution 1-1, 1-2 configuring B-4 service area dimensions C-5 connector B-1 specifications C-2 to C-6 parallel port 1-15 standard features 1-1 PC card slot 1-9 status 2-3 PCL 1-4 support F-1 PCL menu 2-19 warranty F-6 weight C-3 Index-4, printer control language. See PCL resetting, printer A-1 printer exterior, cleaning 5-5 resolution, printer 1-1, 1-2 Printer Menu Settings report E-12 reversing unit area, cleaning 5-5 Printer Setup report E-1 Ripple Test Print report E-16 printing alignment sheets 6-12 S duplex 1-1, 1-2 edge-to-edge 6-23 screen contrast control 1-7 forms 1-1, D-11 serial interface input capacity 1-1 configuring 2-23, B-1 to B-3 reports 2-28 connector 1-9, 1-15, B-1 resolution C-2 specifications speed C-2 best print area C-6 stopping or interrupting 3-21 custom paper tray C-12 Printing menu 2-11 HCI C-7 HCO C-10

R introduction C-1

optional accessories C-7 recycling printer C-2 to C-6 toner 1-3, 6-8 transparencies D-14 removing standby switch 1-7, 2-2 drum 4-21 status fuser 4-30 checking 2-3 paper trays 3-2 messages A-3 replacing printer 2-3 cleaning roller 4-7 stopping, printing 3-21 consumables 1-2 support F-1 developer 4-9 switch drum kit 4-18 main power 1-7, 1-18 fuser kit 4-29 standby 1-7, 2-2 ozone filter 4-17 Symbol Set Table report E-10 pick rollers 4-42 toner 4-4 T toner collector bottle 4-7 transfer assembly 4-19 temperature hazards iv reports Test menu 2-28 Maintenance E-6 toner 4-5, 6-7 Printer Menu Settings E-12 recycling 1-3, 6-8 Printer Setup E-1 removing stray 5-2 printing 2-28, E-1 to E-16 replacing 4-4 Ripple Test Print E-16 toner collector bottle 1-13 Symbol Set Table E-10 replacing 4-7 Typeface E-8 toner fill lid 4-5 toner hopper 1-13 toner hopper area, cleaning 5-2 toner kit 4-3 Index-5, transfer assembly V cleaning 5-6 installing 4-27 virtual font cartridges 6-26 replacing 4-19 transfer assembly guide 1-11 W cleaning 5-9 transparencies, specifications D-14 warning messages iv, A-4 troubleshooting warranty F-6 error messages 3-49 paper problems D-20 print quality 6-1 Typeface report E-8 Index-6, READER COMMENT SHEET System Peripherals Operation D640 Cut Sheet Printer User Manual Manual Part Number C5620-90024 March 1997 A reader comment sheet helps us improve the accuracy and readability of this User Manual. It also gives you a way to make suggestions and recommend improvements to the product. Serious errors, such as technical inaccuracies that may render a program or mechanical device inopera- tive, should be reported immediately to your Hewlett Packard Response Center or directly to a Support Engineer. This ensures that such problems are addressed as quickly as possible. Editorial suggestions (please include page, table, and figure numbers): Recommendations (attach additional information, if needed): Name: Date: Job Title: Telephone: Company: Address: Hewlett-Packard has the right to use submitted suggestions without obligation, with all such ideas becoming the property of Hewlett-Packard., Copyright © 1997 Hewlett-Packard E0397

Manual Part No. Printed in USA C5620-90024

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