Epson WF-3640 Paper Jam Errors When Using High-Quality Print Settings- Causes and Fixes

Question:

I'm using an Epson WorkForce WF-3640 printer, and I'm only able to print when it's set to plain paper. If I switch to other paper types or choose high-quality settings, I get a paper jam error, even though there’s no paper jammed. Is this a known issue?

Answer:

Understanding the Paper Jam Errors at High-Quality Settings

You’re absolutely on point noticing that the paper jam only occurs when using non-default or high-quality print settings. That kind of selective failure is often a sign of a mechanical or synchronization issue, rather than a software or firmware bug.

Here’s what’s likely happening:

• High-quality print settings typically trigger the printer to feed paper more slowly, and the printhead makes multiple passes across the page to achieve finer resolution.

• This added mechanical load can expose weaknesses in the printer’s internal systems—things that don’t appear when printing with normal or draft settings.

The fact that printing works fine on plain paper settings but fails when you increase print quality suggests that components like drive gears, the feed roller system, or encoder timing mechanisms may be compromised.

Mechanical Checks You Can Perform:

1. Open the side or rear panel of the printer and look for:

   • Cracked or worn gears — even a small crack or missing tooth can cause slippage when under extra load.

   • Stripped teeth on timing belts or cogs, especially those that synchronize the paper feed with the printhead carriage.

   • Foreign debris, such as paper dust, label fragments, or ink build-up near the feed rollers or encoder wheel.

   • Make sure the encoder strip and encoder wheel are clean and free of smudges. The printer uses these components for precise positioning; if dirty, it may misjudge movement and throw a “paper jam” error when there’s no physical jam.

2. Manual feed test:

   • Slowly hand-feed a sheet of paper while observing whether the rollers grip consistently and feed smoothly.

   • If you feel resistance or the rollers slip, they may be worn or dirty.

3. Firmware and driver settings:

   • Rarely, mismatched paper settings in the printer driver vs. the control panel may confuse the printer, leading to false jam errors. Make sure both are aligned.

This issue is commonly seen in Epson WF-3640, WF-3620, and related models like the WF-3520, 3530, and 3540—particularly as they age. It may begin subtly (e.g., failing only on photo paper or premium settings) and progress to broader feed failures if the gear damage worsens.

Please note: Fixing issues like these typically involves physical inspection, cleaning, and sometimes replacement of internal components. Because these are hands-on procedures, we're unable to offer remote repair suggestions or detailed one-on-one troubleshooting. However, we do provide in-person diagnostics and repair services through our printer repair service center (https://bchtechnologies.com/printer-repair-service). Due to high demand, service is handled on a first-come, first-served basis, and it may take a few weeks to schedule a drop-off. We offer full printer repair and part-specific servicing with clear procedures. While our pricing may not be the lowest available, we encourage users to explore self-repair when possible. You can find helpful resources by searching our YouTube channel (https://youtube.com/@bchtechnologies). Use the search icon next to the “About” tab to quickly locate content relevant to your printer model. We’ve posted hundreds of videos over the years, and YouTube’s built-in search will also suggest content from other channels that may be helpful.

Thank you again for your detailed observation and for being a valued part of our BCH Technologies community. We're here to support you every step of the way.