Epson Printer Shows Paper Jam During Printing or Head Check After DTF Conversion - Causes and Fixes

Question:
I'm having a paper jam issue with my printer, and it only appears when I try to print something or run a print head check. This is not a phantom paper jam-the error pops up and I can actually see the paper jam inside the printer. I tried cleaning the page width sensor because it had ink on it, and I also cleaned several rollers with alcohol (though I'm not sure if I cleaned the correct ones). The printer is new and I converted it for DTF printing. I'm running out of ideas and want to fix it before the ink sits in the printer for too long. Do you have any suggestions?

Answer:

Since your printer is detecting a real paper jam (not a phantom jam) and you can physically see the paper stop moving, this typically means the printer is encountering actual resistance somewhere along the paper path. The printer's sensors are detecting that the paper is not advancing as expected and triggering a jam error.

In many Epson printers, this can generate errors such as Paper Jam Error, Error Code 0x97 variants, 0xEA carriage movement errors, or general paper feed failure alerts, depending on the model. These errors are often triggered when the printer detects that the paper did not reach a sensor within the expected time window.

Since you already cleaned the page width sensor and some rollers, that was a good first step. However, there are several other areas that commonly cause this issue-especially after a DTF conversion.

1. Check the Encoder Strip (Carriage Position Sensor)

One frequently overlooked component is the encoder strip, which is the thin transparent plastic strip running behind the printhead carriage.

During DTF conversions, ink mist and overspray often accumulate inside the printer. This mist can settle on the encoder strip and interfere with the printer's ability to accurately track the printhead position.

When the printer cannot correctly determine the carriage location, it may interpret this as a paper feed or carriage movement problem, which can trigger paper jam errors.

How to clean it:

1. Turn the printer off and unplug it.

2. Locate the thin clear strip behind the carriage.

3. Use a lint-free cloth or foam swab lightly dampened with isopropyl alcohol.

4. Gently wipe the strip from one end to the other.

5. Avoid pulling or dislodging the strip.

If the encoder strip is heavily contaminated with ink mist, cleaning it often resolves strange feeding errors.

2. Inspect the Entire Paper Path for Debris

Since the printer physically jams the paper, there may be small debris or hardened ink deposits interfering with the paper movement.

Things to check include:

• Small pieces of paper or label backing

• Hardened ink droplets from DTF overspray

• Dried cleaning solution residue

• Misaligned paper guides

DTF conversions tend to produce more ink vapor inside the printer, which can settle along the feed path and gradually build up friction.

Carefully inspect:

• The entry rollers

• The mid-feed rollers

• The exit rollers

• The platen area under the carriage

Even a tiny obstruction can cause the paper to stall.

3. Check the Paper Feed Sensor Flags

Epson printers use small plastic levers (sensor flags) along the paper path. When paper passes through, these flags move and signal the printer that paper is advancing correctly.

If one of these flags becomes:

• Stuck

• Blocked with ink

• Misaligned

the printer will immediately report a paper jam.

These flags are often located:

• Near the paper pickup area

• Midway along the paper transport path

• Near the exit rollers

Try gently moving them with a small tool or tweezers to confirm they move freely and spring back into place.

4. Observe Exactly Where the Paper Stops

A very effective troubleshooting technique is simply watching the paper path during a feed attempt.

Load paper and initiate a print or nozzle check, then observe:

• Does the paper fail to feed from the tray?

• Does it enter the printer but stop midway?

• Does it stop right before exiting?

The exact stopping point usually corresponds to the faulty sensor or roller area.

For example:

5. Confirm the Rollers You Cleaned

Many people clean only the visible rollers, but Epson printers typically have multiple sets of rollers:

• Pickup rollers

• Transport rollers

• Pressure rollers

• Exit rollers

Some of these are partially hidden.

If the paper slips instead of feeding smoothly, cleaning all accessible rollers with isopropyl alcohol can improve traction.

6. DTF Conversion Considerations

Since the printer was converted to DTF printing, additional factors may contribute to feeding issues:

• Ink overspray accumulating on internal components

• Slight paper thickness differences (DTF film vs normal paper)

• Modified firmware settings affecting feed timing

DTF film also requires stronger grip from the rollers, so any contamination reduces traction significantly.

Addressing printer issues can be a complicated affair due to the hands-on nature of the problems. Because of that, we're not able to provide remote troubleshooting, repair suggestions, or direct technical support for printer repairs. However, we do offer in-person diagnostic and repair services through our local facility: BCH Technologies Printer Repair Service (https://bchtechnologies.com/printer-repair-service).

Due to high demand, we operate on a first-come, first-served basis, and it may take a few weeks before we are able to accept a printer for drop-off. Our service structure allows us to repair either a complete printer or individual components, and we provide clear instructions for customers sending in equipment. That said, we recognize that our repair services may not always be the most economical option. Therefore, we strongly encourage exploring self-help resources online.

A great place to begin is YouTube, especially our channel homepage: BCH Technologies YouTube Channel (https://youtube.com/@bchtechnologies). Once there, you can use the search icon next to the "About" tab to find videos related to your specific printer issue. I receive dozens of questions every day asking whether we have a video on a particular topic. After producing repair videos for more than nine years, it's difficult to remember every single one! Using YouTube's built-in search is usually the fastest way to locate relevant content, and it may also suggest helpful videos from other creators.

Thanks again for reaching out and for supporting our channel. We truly appreciate your engagement with the BCH Technologies community, and we wish you the best of luck getting your printer running smoothly again.