Fix Paper Jamming and Folding in Photocopier Machines: A Step-by-Step Guide

Updated at: 09/02/2025

Paper jams and folded prints are frustratingly common occurrences with photocopier machines, halting productivity and causing unnecessary delays. These issues, often stemming from simple causes like overloaded trays or misaligned paper, can seem daunting to troubleshoot, leaving you staring blankly at the blinking error lights. However, with a methodical approach, most paper handling problems can be resolved quickly and easily, minimizing downtime and preventing further complications. These problems can range from minor inconveniences to significant workflow disruptions.

This guide provides a clear and concise, step-by-step process to diagnose and fix common paper jams and folding problems in your photocopier. Whether you're dealing with a stubborn jam in the feed tray or consistently folded output, following the detailed instructions below will empower you to swiftly return your machine to full functionality.

Preparation and Safety Guidelines

Tools Needed
  • photocopier machine
  • cutting tool
  • cloth
  • thinner
  • blower
Safety Guidelines
  • Always turn off and unplug the photocopier before attempting to clear a jam or fold. Electricity can cause serious injury.
  • Never force anything. Gently remove jammed paper; forcing it could damage internal components.
  • If you are unsure about any step, consult your photocopier's manual or contact a qualified technician.

Step-by-Step Instructions

  1. Prepare the Machine

    • Turn off and open the photocopier machine.
    Turn off and open the photocopier machine.
    Prepare the Machine

  2. Remove Heater Unit

    • Remove the jack of its rod (located on the side).
    • Open the nut on the other side of the machine and remove the earth wire nut.
    • Open the nut holding the heater unit and remove the thermistor and sensor wires.
    • Remove the heater unit (carefully, as it may be hot). Let it cool for 5-10 minutes if necessary.
    Remove the heater unit (carefully, as it may be hot). Let it cool for 5-10 minutes if necessary.Remove the heater unit (carefully, as it may be hot). Let it cool for 5-10 minutes if necessary.Remove the heater unit (carefully, as it may be hot). Let it cool for 5-10 minutes if necessary.Remove the heater unit (carefully, as it may be hot). Let it cool for 5-10 minutes if necessary.
    Remove Heater Unit

  3. Clean Ink and Obstructions

    • Clean the ink-applied strip thoroughly using a cutting tool to remove any dried ink.
    • Clean the heater roller by wetting a cloth with thinner to remove accumulated ink. Be careful with thinner, it's flammable.
    • Open and clean the comb mechanism to remove any obstructions or stuck ink.
    Open and clean the comb mechanism to remove any obstructions or stuck ink.Open and clean the comb mechanism to remove any obstructions or stuck ink.Open and clean the comb mechanism to remove any obstructions or stuck ink.
    Clean Ink and Obstructions

  4. Clean Gear Assembly and Sensor

    • Remove and clean the gear assembly, paying attention to any ink buildup or obstructions.
    • Check and clean the sensor, ensuring no dust or debris is interfering with its operation.
    Check and clean the sensor, ensuring no dust or debris is interfering with its operation.Check and clean the sensor, ensuring no dust or debris is interfering with its operation.
    Clean Gear Assembly and Sensor

  5. Reassemble the Machine

    • Reassemble the photocopier in reverse order of disassembly, ensuring all components are correctly placed and secured.
    Reassemble the photocopier in reverse order of disassembly, ensuring all components are correctly placed and secured.
    Reassemble the Machine
[RelatedPost]

Tips

  • If the paper jams without folding, you likely have a sensor issue.
  • Ink buildup on the heater roller is a common cause of paper folding.
  • Clean all components thoroughly to prevent future jamming.
  • Always let the heater unit cool down before handling.

Common Mistakes to Avoid

1. Ignoring Small Paper Jams

Reason: Trying to force the paper through instead of properly opening the machine and removing the jammed sheet can lead to more damage and tearing.
Solution: Always fully access the jam location and gently remove the jammed paper, avoiding tearing or forceful pulling.

2. Improper Paper Loading or Using Incorrect Paper

Reason: Loading paper incorrectly, using the wrong paper type (too thick, too thin, damp), or overloading the tray causes frequent jams and folding.
Solution: Ensure the paper is correctly aligned and loaded into the tray, following the machine's manual for paper type and loading capacity.

FAQs

Why does my photocopier keep jamming?
Paper jams are usually caused by issues like using the wrong type or size of paper, overloaded paper trays, damaged rollers, or a sensor problem. Make sure you're using the recommended paper and that the paper trays aren't overcrowded. Check the rollers for debris or damage, and if the problem persists, it might be a sensor issue requiring professional attention.
While this guide focuses on resolving frustrating paper jams and folds in your everyday photocopier, consistent issues might indicate a need for a more robust solution, especially for high-volume printing or specialized folding requirements. If you regularly handle large print jobs demanding precise folding, you might find our previous article on top-rated paper folders for creating professional catalogs in 2024 helpful. Understanding the mechanics of proper paper handling, as detailed here, will improve your results regardless of the equipment you use.