Epson Printer Manual Feed Problems, 100 lb Cardstock, Rear Feed Issues, and Output Tray Not Opening

Question

I have a few questions about my printer. First, do you think this printer can reliably print photo-quality images on 100 lb cardstock? Second, the printer has stopped recognizing the manual feed. Even when I select manual feed in the printer driver, it still tries to pull paper from the rear feed. I have the latest drivers installed, and the printer is currently connected by Wi-Fi, though I also have a Cat 6 Ethernet option available. The rear feed is also not feeding paper consistently. Sometimes it spits the paper back out, although I was able to get a couple of prints from it.

I have also been trying to observe the printer's internal parts and clean the rubber roller without taking anything apart, but it was hard to reach. While doing this, I touched a small white tab on the inside left under the scanner, and it slipped out of place. I used a chopstick to put it back where it had been. I also disconnected power to unlock the ink tank area so I could inspect the right side, which I have done on previous models without any problems. After doing these things, the output tray no longer opens.

I am interested in your repair service to help get this printer running again. I would also appreciate any thoughts on regular maintenance. I am comfortable taking things apart and putting them back together if I have clear instructions, but this printer seems more delicate and complicated than others I have worked on.

Answer

Regarding 100 lb cardstock, the printer should be capable of handling heavy card stock to some degree, especially if the media path is as straight as possible and the correct paper type is selected in the driver. However, I have not tested your exact setup in intensive, long-term production with 100 lb cardstock, so I would be careful about calling it "reliable" for repeated heavy use without testing. Photo-quality printing on thick media puts extra demand on the feed rollers, paper sensors, platen gap, and feed timing. A printer may handle one or two sheets successfully but become inconsistent when the paper coating, stiffness, humidity, or curl changes.

For heavy cardstock, the manual sheet feed is usually the better option because it gives the paper a straighter path and reduces the amount of bending the sheet has to go through. Many people do not realize that this printer has another feed path from the back. You can remove the duplexer and feed from the back using the manual sheet feed, sometimes referred to as MSF. This is often better for thick paper than trying to force heavy media through a more curved feed path.

However, the manual feed system depends on sensors. If the printer does not detect the sheet correctly, it may ignore the manual feed request and try another tray or feed source instead. Even if you select manual feed in the driver, the printer still needs confirmation from its internal sensors that paper is actually present in the correct location. If a sensor flag is sticky, blocked, bent, dusty, or out of position, the printer may behave as though no manual-feed paper was inserted.

The fact that the printer is trying to pull from the rear feed even when manual feed is selected suggests one of several possibilities. The driver setting may not match the printer's physical paper-source detection, the manual-feed sensor may not be triggering, the paper may not be inserted far enough or at the correct time, or one of the feed-path flags may not be returning to its normal position. With printers that have multiple paper paths, the source selection is not just a software decision. The printer also checks mechanical switches, optical sensors, and sometimes paper-position flags before it commits to a feed path.

The rear feed spitting paper back out is another sign that the printer may be detecting a feed error or registration problem. This can happen when the pickup roller is dirty, glazed, or losing grip. It can also happen if the separation pad is worn or contaminated, if the paper is too stiff, if the sheet has curl, or if the leading edge is not being presented squarely. For cardstock, even a small amount of curl can cause the printer to reject the paper or misread the leading edge. Coated photo cardstock can also be slick, so the roller may slip instead of pulling it cleanly.

Cleaning the rubber rollers is a good maintenance step, but it has to be done carefully. A lint-free cloth lightly dampened with water is usually the safest first approach. Avoid soaking the roller area because liquid can drip onto sensors, boards, or mechanical parts. If the roller surface is glossy, dusty, or covered with paper coating residue, it may not grip properly. Rotate the roller as much as possible while cleaning so the entire circumference is cleaned. If the roller is hardened, cracked, or permanently glazed, cleaning may not be enough.

The small white tab you touched under the scanner is important. These white tabs are often sensor flags, paper-path levers, tray-position indicators, or mechanical actuators. Even if it looks like it was put back in place, it may not be seated exactly on its hinge or spring point. A tab that is slightly out of position can cause the printer to think a cover, tray, paper path, or internal mechanism is not in the correct state. These printers can be very sensitive to small alignment errors.

I do not think the ink tank sensor itself would normally cause the front output tray to stop extending. The output tray mechanism is usually controlled by its own motor, gear train, position sensor, or tray-detection system. However, if something was disturbed while the scanner section was lifted or while you were inspecting the inside, a nearby sensor flag, cable, lever, or gear may now be out of place. The printer may also refuse to open the output tray if it thinks another part of the printer is not seated correctly, such as a cover, scanner unit, duplexer, rear assembly, or internal paper-path component.

For the output tray issue, I would check the simplest things first. Make sure the printer is powered normally and not in an error state. Reinstall the rear duplexer or rear cover securely. Open and close the scanner unit and all covers, making sure they latch cleanly. Check whether the output tray is physically jammed or being blocked. If the tray motor tries to move but clicks, grinds, or stops, that points toward a mechanical obstruction or gear issue. If there is no movement at all, it may be a sensor, motor, cable, or logic-board command issue.

Since the problem began after the internal inspection and the white tab slipping out of place, I would pay close attention to that area. Check whether the tab moves freely and springs back to its original position. It should not feel loose, jammed, or disconnected. If it is a sensor flag, it must interrupt or clear the sensor at the correct moment. If it is not seated correctly, the printer may misread the machine's internal state.

For the manual feed and rear feed problems, I would focus on three areas: sensors, rollers, and paper path alignment. First, inspect the manual-feed sensor area and any visible plastic flags to make sure nothing is stuck. Second, clean the pickup rollers and paper-feed rollers as well as you can reach safely. Third, test with plain paper first before testing cardstock. If plain paper feeds reliably but 100 lb cardstock does not, then the issue may be media thickness, stiffness, paper curl, or roller grip under heavier load. If plain paper also fails, then the printer likely has a mechanical or sensor-related feed problem.

For driver settings, make sure the paper source, paper size, and paper type match exactly. If the driver is set to one paper size but the printer detects another, or if the paper type is not appropriate for heavy media, the printer may reject the sheet or switch sources. For heavy photo cardstock, try selecting a thicker paper or premium photo paper setting if available. Also check whether the application's print dialog is overriding the printer driver. Sometimes the printer driver says one tray, but the application or operating system sends a different source command.

Your Wi-Fi versus Cat 6 Ethernet connection should not normally cause a mechanical feed issue. A network connection problem can delay jobs, interrupt communication, or cause driver confusion in some cases, but it would not usually make the rear feed spit paper back out. The feed behavior is much more likely related to the paper path, rollers, sensors, or printer settings.

For regular maintenance, I would recommend keeping the paper path clean, using good-quality flat paper, storing cardstock in a dry place, and avoiding curled or warped sheets. Clean the rollers periodically, but avoid aggressive solvents unless you know the material is safe for that roller. Keep dust and paper fibers out of the rear feed and manual feed areas. If you print photo-quality work often, also run nozzle checks regularly and avoid letting the printer sit unused for long periods. For inkjet printers, consistent use is one of the best forms of maintenance because it helps reduce clogging.

Since you mentioned that you are comfortable taking things apart with clear instructions, I still want to caution you that this model can be more delicate than older printers. Newer printers often have more sensors, thinner plastic tabs, ribbon cables, and interlocked assemblies. A part can look like it is back in place but still be one notch off, and that can create tray, feed, or sensor errors. If you continue working on it yourself, take photos before moving anything, avoid forcing any lever or tray, and test one change at a time.

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Addressing printer issues can be a complicated affair because many of these problems require hands-on inspection. For that reason, we are not able to provide remote troubleshooting, step-by-step repair supervision, or individualized remote support for printer repairs. We do offer in-person evaluation and repair through our local diagnostic facility: BCH Technologies Printer Repair Service [https://bchtechnologies.com/printer-repair-service]. Because demand is high, we operate on a first-come, first-served basis, so it may take a few weeks before we can schedule your printer for drop-off. Our services are structured to repair either a whole printer or specific parts, with clear instructions on how to proceed. However, we also understand that our rates are not the most economical option. For that reason, we strongly recommend self-help through online research whenever possible. You can start with YouTube or visit our YouTube homepage at BCH Technologies on YouTube [https://youtube.com/@bchtechnologies]. Use the search icon next to "About" on the right-hand side of the menu bar to look for specific repair topics. I receive dozens of questions every day asking which video covers a particular issue. Since we have created videos for the past nine years, it is difficult to remember every single one, so YouTube's search function is usually the most efficient way to find the right video. YouTube may also suggest helpful videos from other channels that apply to your situation.

Thank you again for reaching out and for explaining the symptoms in detail. Based on what you described, I would investigate the manual-feed sensor, rear-feed rollers, paper-path flags, and output tray mechanism before assuming the printer has a major electronic failure. I appreciate your support and hope this gives you a clearer path for deciding whether to continue with careful self-service or send the printer in for evaluation.