How to Fix Epson WF-3640 Paper Jam Errors When Printing in High-Quality Settings

Question:

I’m using an Epson WorkForce WF-3640 printer. It prints fine when set to "plain paper" mode, but when I switch to a higher quality setting or select other paper types, it gives me a paper jam error, even though there’s no paper jam. Is this something you’ve encountered before?

Answer:

Why You Get Paper Jam Errors Only in High-Quality Print Settings

You’ve made an excellent observation. Yes, it's actually quite common for printers like the Epson WorkForce WF-3640 (and similar models such as WF-3620, 3010, 3520, 3530, and 3540) to behave differently depending on the print quality or paper type selected.

When you switch from plain paper to settings like photo paper, premium glossy, or high-resolution, the printer enters a different operating mode:

• Feed speed slows down to improve print precision.

• Printhead makes multiple passes over the same section.

• Increased torque/load is placed on internal feed gears.

If there's a problem like a worn gear, stripped gear tooth, or a timing mismatch, this extra strain can push the hardware beyond its limits—resulting in the printer triggering a false paper jam error.

Mechanical Areas to Inspect

Here’s what we recommend:

1. Check the Drive Gears and Roller Assembly:

   • Open the side or rear panel of your WF-3640.

   • Look closely at the paper feed drive gears—especially the ones controlling the rear and main feed rollers.

   • If any gear has a missing or cracked tooth, it can slip under heavy load (like during high-quality printing) and make the printer think a paper jam occurred.

2. Inspect the Encoder Strip and Encoder Wheel:

   • These components are responsible for synchronizing the movement of the printhead and the paper.

   • If the encoder strip or wheel is dirty or partially blocked by debris, the printer might misread position data and assume the paper is misaligned or jammed.

3. Clear Paper Dust and Ink Residue:

   • Sometimes, residual buildup on the rollers or sensors can interfere with smooth operation. Clean all feed rollers with a lint-free cloth dampened with water or isopropyl alcohol.

4. Test with Various Settings:

   • Try printing with “plain paper” selected but manually increase the quality to “high” and monitor if the error still appears.

   • This will help you narrow down whether it’s the media type, resolution setting, or both triggering the problem.

Related Error Codes

Although you didn’t mention a specific error code in this case, users with similar issues sometimes encounter:

• 0x69: Indicates a mechanical jam or obstruction in the print mechanism.

• 0xEA or 0xF1: Typically show up when the carriage or encoder has trouble tracking movement—often tied to timing issues or sensor failure.

If you’ve seen any of these pop up alongside the jam warning, it further supports the theory of a mechanical synchronization issue.

Please note: Printer malfunctions like these often require direct inspection and hands-on testing. Therefore, we’re unable to offer remote one-on-one troubleshooting. However, we provide an in-person diagnostic and repair service at our local printer repair facility (https://bchtechnologies.com/printer-repair-service). Due to high demand, repairs are accepted on a first-come, first-served basis, and it may take a few weeks to schedule a drop-off. Our services are built to support both full-unit repairs and individual component servicing, with clear steps for customers. That said, our pricing may not suit every budget. For that reason, we highly recommend exploring DIY repair options through online research. You can begin by visiting our YouTube channel homepage (https://youtube.com/@bchtechnologies). Use the search icon next to the “About” section to quickly locate videos for your printer model. With hundreds of uploads over the past nine years, the search tool is your best bet for finding the exact guidance you need—and you may even find helpful videos from other creators as well.

Thanks again for sharing your experience with us. Your input helps others in the community facing the same issue, and we’re always here to help however we can.