Epson ET-8550 Paper Feeding Problems - Causes and Solutions

Question:
After cleaning the paper eject sensor on my Epson ET-8550, some error messages were resolved. However, I'm still experiencing these issues:

1. When printing from the rear tray, the tray clicks, crinkles the pages, and sometimes pulls in multiple sheets before eventually printing on one.

2. When printing from cassette 2, the printer often pulls in extra pages, causing jams. For example:

   • In duplex printing, instead of flipping the sheet, it pulls in a new page and jams.

   • If both cassette 2 and the rear tray contain paper, it sometimes pulls sheets from cassette 2 even when printing from the rear tray, leading to jams.

Could this be caused by something I did when cleaning the duplexer, or is it still a paper edge sensor issue that requires replacement rather than cleaning?

Answer:

The problems you describe-paper crinkling, multiple sheet feeding, and misrouting between trays-point toward a combination of paper handling mechanism issues and sensor-related faults. Let's break them down:

1. Rear Tray Clicking and Crinkling Pages

• The clicking sound is usually from the pickup roller mechanism trying to engage but slipping, either due to wear, dirt, or misalignment.

• Crinkling often happens when the feed rollers or separation pads are dirty, glazed with ink residue, or losing grip. This causes the printer to pull multiple sheets or partially feed pages before stopping.

• If you recently removed or cleaned the duplexer, it's possible that a roller or guide was misseated, creating extra resistance. Double-check that all rollers and plastic guides are firmly locked in place.

2. Multiple Pages Feeding from Cassette 2

• This strongly suggests an issue with the paper separation pad or pickup roller in cassette 2. These components are responsible for ensuring only one sheet is grabbed at a time.

• If the pad is worn smooth or the roller is dirty, the printer can't properly separate sheets, leading to jams. Cleaning with isopropyl alcohol can help, but in many cases these parts need replacement.

3. Duplex Printing Jams

• During duplexing, the paper edge sensor and timing sensors ensure the sheet re-feeds correctly. If the edge sensor is still malfunctioning, the printer may misinterpret the paper position and mistakenly try to feed a new sheet instead of flipping the current one.

• This explains why you see jams specifically during double-sided jobs. Cleaning helps, but if the sensor's optical surface is scratched, worn, or misaligned, replacement is the only long-term fix.

4. Rear Tray and Cassette 2 Interference

• When printing from the rear tray while cassette 2 is loaded, the printer shouldn't draw from cassette 2. If it does, it points to a tray detection or sensor misread.

• This again circles back to the paper edge/paper eject sensors, which coordinate tray switching. If these sensors are not functioning correctly, the printer may mistakenly think the rear tray is empty and pull from cassette 2.

Most Likely Root Causes

• Worn or dirty feed rollers/separation pads (causing multiple pages to feed).

• Paper edge sensor still malfunctioning (causing wrong tray pulls and duplex jams).

• Possible misalignment from duplexer reinstallation (causing clicks and misfeeds).

If cleaning hasn't solved it, the next step would be replacing the paper edge sensor and the separation pads/pickup rollers. Epson sells maintenance kits that include these parts, or you can source compatible replacements.

Addressing printer issues can be tricky because they require physical inspection and testing. For that reason, we aren't able to provide direct remote repair guidance. However, we do offer in-person diagnostics and repair through our local service facility (https://bchtechnologies.com/printer-repair-service). Please note that service is on a first-come, first-served basis, and depending on demand, it may take a few weeks before we can begin work on your printer. Our repair service covers full units and individual parts, and we'll provide detailed instructions if you decide to proceed. That said, our service rates may not be the most budget-friendly option, so we also recommend researching self-repair options online. You can start with our YouTube channel (https://youtube.com/@bchtechnologies), using the search function next to "About" to find specific videos. With nearly a decade of tutorials, this is the fastest way to locate resources, and YouTube may also point you toward helpful videos from other repair professionals.

Thank you again for your thoughtful question and for supporting BCH Technologies. We truly appreciate your trust and are glad to help guide you through these complex printer issues.