ACSI Refill Instructions
HP 51640A, HP 51645A, HP 51645G, and HP 51650A Cartridges
Also HP C6615A Cartridges.
HP Deskjet 700, 800, 1000, 1200, and 1600 Series Printers and DesignJet Plotters
Updated May 13, 1999
These cartridges are virtually identical and refill the same. The ink in
these cartridges is retained because the cartridge develops a
slight vacuum. These cartridges are sealed plastic boxes.
We offer a selection of 3 inks for these cartridges.
Having said all of this, what do we recommend?
- WJ-1010 is a premium pigmented ink which is an extremely close match to
the performance of the original HP ink. This ink will give excellent Ultra-violet
resistance to fading, and good water resistance. A word of caution: Because the pigments
tend to carbonize in the print head if printing continues with a
dry cartridge, it is important to refill immediately when using this ink. This
ink is also more expensive than the other two inks.
- WJ-163 is a dye-based ink which is also an excellent performance match
to the original HP ink under most conditions. This ink is oriented toward
text printing and drys quickly, leaving the dye on top of the paper. Thus,
it tends to be less water-resistant than the other two inks, but offers
excellent text printing. It also tends to sit on top of color inks and will
sometimes smudge when printed on an ink background.
- WJ-138 is a dye-based ink which was developed to provide better graphics
performance than WJ-163. Because it drys a bit slower, it will tend to
blend into color graphics and soak deeper into the paper, smudging less.
However, it will give slightly inferior text-on-white-paper performance
than WJ-163 since the WJ-138 tends to spread more before drying. WJ-138 also
gives good water-resistance because more of the ink has soaked deeper into
Most people will find that WJ-163 is the best choice for their general
purpose printing. If you require professional quality output, a high
degree of fading protection, or a water resistant ink, consider
the WJ-1010. If you print lots of graphics, particularly with black text
on a printed background, consider WJ-138.
Unless you otherwise specify when ordering, we will ship WJ-163 ink.
Step 1) Put the cartridge on some paper towels in an area where you
can tolerate a spill. Be sure that you are wearing old clothes, since the
first time you fill the cartridge, you will probably get some ink on your
clothes and hands. You may wish to wear rubber gloves if you don't wish to
stain your hands. We also don't recommend refilling as a family project --
it's amazing what a three-year-old can do with a pint bottle of highly
concentrated ink! See our General Information for more details.
Step 2) Turn the cartridge upside down.
- Locate the rectangular copper printhead where the ink comes out.
- Behind the printhead is a black plastic rectangular well.
- Behind the rectangular well is a round black dimple in the center of the cartridge
bottom.This round black dimple
looks similar to a mold release mark from the plastic mold. In
reality, this dimple is a small piece of black rubbery plastic which
conceals the original fill hole of the cartridge!
Step 3) Remove the black dimple plug over the fill hole. You may need
to scrape it off with a knife or screwdriver.
Step 4) Push the ball in the fill hole into the cartridge with a ball
point pen or similar device. Forget about it.
Step 5) Inject 30 ml (one syringe bottle) of the ink into the fill hole
slowly. You may add an additional 5 ml if the cartridge will take it. Fill
to the bottom of the fill hole.
Step 6) Now you must seal the fill hole air tight. We suggest using
silicon rubber, hot glue, or (preferred) a 10-32 x 1/2 inch long (M6) set screw.
(Stainless steel is preferred for longer life, but regular steel will do.
These set screws should cost you 25 cents or so at the local hardware or
home center store.) The set screw will self-tap and form an excellent
plug which can be removed and re-installed each time you refill. Do
not use a screw with a round or flat head! Only use a set screw so that
this can be recessed below the surface of the cartridge.
Whichever you decide to use, you should squeeze and hold the cartridge just before
sealing to set up the vacuum. Make sure the seal is flush or just below the
Step 7) After sealing, release the sides of the cartridge and squeeze again, twice.
A couple of drops of ink should come out of the printhead.
Step 8) You might wish to set the cartridge over a paper towel for an
hour as a drip precaution. Expect a few
drips until the vacuum stabilizes. Before inserting the cartridge, blot off
the hanging drop of ink with a paper towel.
Step 9) When inserting the cartridge, first tilt the cartridge so that
the ball is caught above the set screw and doesn't roll into the area
above the print head, where it can occasionally block off some ink flow.
Step 10) Immediately run the printhead cleaning software. (Go to the HP
software and select "Services".)
There are several problems which can occur with this cartridge.
Incorrectly Installed Cartridge
Occasionally you will receive a message which indicates that you
have incorrectly installed your cartridge, or that the cartridge is
bad. Try the following steps to correct this error.
- Remove and re-install the cartridge. Be sure to put the cartridge
completely back into the slot before lowering the lever.
- Check the copper pads on the back of the cartridge for problems.
- Ink buildup -- Remove with tissue and warm water. Do not use
cleaning sprays. Dry before re-inserting.
- Holes in the copper pads. Occasionally, a hole will be punched in
one of the copper pads. If this is your problem, the cartridge is damaged beyond
repair and needs to be replaced.
- If these problems have been checked and the problem persists, take
a stiff, dry paper towel and buff the pads to remove oxidation buildup.
- If the problem persists, unplug the printer. Then, check the pins
which are in the printer and normally touch the copper pads on the
cartridge. Look for obvious problems such as bent pins, debris, or
ink build up. Buff the tips of the copper pins gently with a stiff,
dry paper towel. Re-insert the cartridge and plug in the printer. Try
- If all else fails, you may have a bad cartridge. Occasionally,
the cartridge fails internally if printing is attempted when dry.
Cartridge doesn't Print
Follow the instructions below for cleaning the printhead.
Cartridge prints in Streaks or Bands
Follow the instructions below for cleaning the printhead.
Skips on Horizontal Lines
This cartridge has an interesting and slightly annoying problem which
develops in about 50 percent of the cartridges on only the
first time they are refilled. The symptom goes as follows:
When printing long horizontal lines, the printer prints for a couple of
inches (5 cm) and then skips an inch or so (2 to 3 cm). Then the printer
resumes printing the line. The problem only occurs on black lines and only
occurs the first time the cartridge has been refilled.
This problem is caused because of two things which come together in this
These two problems combine to cause a bit of foaming between the filter
and the printhead when the cartridge is refilled the first time. This
foam blocks the ink flow to the printhead, and on long prints which pull
a considerable volume of ink -- such as long horizontal black lines -- the
flow of ink to the printhead can be temporarily cut off.
- The original HP ink has a tendency to foam.
- There is a tiny filter located just above the printhead, which traps
a small bit of air when the cartridge is refilled.
Our WJ163 and WJ138 inks for this cartridge have had anti-foaming agents
added to reduce and eliminate this problem. However, the presence of 5 to
10 percent remaining HP ink when the cartridge is first refilled is enough
to trigger the problem. But all reports are that the problem disappears
with the second refill of the cartridge, probably because the original HP
ink has been flushed out of the cartridge.
Be aware of this problem and recognize that the problem will resolve itself.
To Clean the Printhead
Clean the printhead only if the cartridge doesn't print or prints in
- Follow the directions in the printer manual.
- Locate your printer software and select Printer Services. Then
run the printhead cleaning software.
- If that doesn't work, here's a quick and easy method to try next:
- Turn on the hot water faucet and let the water get good and hot.
- Stick just the copper printhead under the hot water for 3 to 5 seconds.
- Remove the printhead and dry with a tissue.
- Re-insert in the printer and run the printhead cleaning routine.
- Print 2 pages. You should get dilute print for a half page or so and
then good quality printing.
- If this doesn't work, soak only the printhead in simmering water for
up to 2 hours. You may add up to 50 percent ammonia for tough clogs. But
don't do this if you haven't run the printhead cleaning software first.
To Clean Your Sink
The ink is water-soluble. Use plenty of soap and warm water. You may also
need to use Comet or a similar cleaner if the stains persist.
To Clean Your Hands
On hands, the best substance to use is
Ink Be GoneTM, a
specially developed hand cleaner available from ACSI Bulk Inks.
(To place an order, Click Here.)
To Place An Ink Order
You can telephone us at 1-888-728-2465 (USA Tollfree) or 1+740-374-9949. You
can also Order Online
or by other ways including
by Fax, or by
Postal Mail, or by