How can I rig a dot matrix printer so the pages don’t get jammed in it?
. I have a dot matrix printer at work that was manufactured by Panasonic in 1985. Every day, the paper jams in it multiple times for one of two reasons: 1)the paper that’s already been printed on folds over and tangles itself in the rollers, or 2)one of the track feeds on the sides of the page tears and backs up the printer. I manually untangle the pages by turning the roller, but it’s very time consuming and becoming a huge hassle. How can I arrange the printer so the pages don’t get stuck anymore?
I’ve already tried: manually resetting the pages, pulling the pages away from the printer until there is enough weight for the pages to fall away from the printer on their own (doesn’t always work though), and yelling at the printer 
There are multiple causes for the problems you’re experiencing, as well as several things/tricks to help prevent them. I’ve worked on dot matrix printers for years and am aware of many of the causes and tricks to help with those problems.
One problem, where the paper is getting stuck on the tractor feeds (you referred to them as track feeds), can be caused by having the paper pulled too tightly between the two tractors, or set too loosely. The paper should be pulled slightly taught between the two tractors then loosened just a bit so that the paper holes can be pulled off and placed back on the tractor tips without resistance. The other thing to look at is the tractor tips themselves as they can become worn around the base from the paper slowly cutting into them causing small cuts or gouges that can grab the paper and pull it in to the tractor mechanism when it should be sliding off as the belts begin the turn around the pulley. The tractors would need to be replaced in that case.
The second problem where the paper at the exit feeds back into the printer is caused by a few things. They are friction and static. As the paper moves through the printer it has friction which causes static buildup in the paper. The friction is also found at the exit where it slides across the plastics. Making sure the paper has enough fall from the rear of the printer so the weight of the paper helps pull itself out of the printer is a start, but it needs to be a minimum of at least 2 feet of fall to be of any significant use.
The other part of the friction thing is the static buildup. To help reduce that problem, the paper should be stacked from the output onto a metal rack that is grounded to the printer or wall electrical ground to help remove the static buildup in the paper as it stacks. The other trick that was used was to string a grounded and conductive wire tinsel inside a spiral wire under the paper across the rear of the printer where the paper would normally come into contact with the printer plastics. This would help keep the paper from building static and clinging to the printer plastics.
Another thing you should have checked is the paper path platen gap between the printhead and the platen roller. If it’s too tight it can cause the paper perforations to tear or pull the paper off the tractors.
The one other thing you should be doing is to make sure the paper has a free, clear and unrestrictive path from the supply box. If the box top is not cut correctly or has slight folds or flaps that can interfere with or provide resistance of the paper leaving the box, it can pull the paper off the tractors or cause it to tear at the perforations and cause it to jam.
Hope that gives you some things to try and be aware of.
Best of luck.
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