Xerox Error 077-900 / 077-901: Paper Jam in Exit Path Step-by-Step Fix Guide

If your Xerox printer or copier is displaying error 077-900 or 077-901 on the control panel, it means the device has detected a paper jam in the exit path area of the finisher or output module. This is one of the most common 077-series errors reported across London offices, and it affects nearly every Xerox commercial device that uses a finisher unit.

The good news is that this error is almost always user-clearable. You do not need a Xerox engineer for this fix in most cases. This guide walks you through the complete step-by-step process to clear the jam, identify why it happened, and stop it from recurring.

This post is part of our complete Xerox Error Codes Repair Guide for London Offices, which covers every major Xerox fault code across all four commercial device families.

What Does Xerox Error 077-900 / 077-901 Mean?

Error 077-900 and 077-901 both indicate a paper jam in the exit path of the finisher or output delivery area. The device has detected that a sheet of paper has not successfully exited the finisher unit within the expected time window.

The Difference Between 077-900 and 077-901

While both codes point to the exit path area, there is a subtle difference between the two.

In practical terms, the clearance process is identical for both codes. The difference only matters for diagnostic purposes if the jam keeps recurring, because it tells you which specific roller set is likely causing the problem.

Which Xerox Devices Show 077-900 / 077-901?

These error codes appear on any Xerox device fitted with a finisher unit. If your device prints directly to an output tray without a finisher, you will not see 077-series codes. The affected device families include:

If you are not sure which finisher your device has, check the model label on the front or side panel of the finisher unit itself. You can also find this information in the device configuration report, which you can print from the touchscreen under Device > Information Pages.

Step-by-Step Fix: How to Clear Xerox Error 077-900 / 077-901

Follow these steps in order. The entire process takes 3 to 5 minutes. You do not need any tools.

Step 1: Do Not Power Off the Device

Unlike many other Xerox error codes, you should not power off the device to clear a 077-900 or 077-901 jam. The finisher is a separate mechanical module, and the jam clearance is designed to be performed while the device is powered on. The touchscreen will guide you through the process with on-screen animations.

Step 2: Open the Finisher Front Cover

Locate the finisher unit attached to the left side or rear of your Xerox device. Open the finisher front cover. On most models this is a large hinged door on the front face of the finisher. It may have a green or blue release handle.

On AltaLink devices with the BR Finisher, the front cover opens downward. On WorkCentre devices with the Office Finisher, it swings open to the left. On VersaLink devices, the finisher front panel pulls forward.

Step 3: Locate the Jammed Paper

With the front cover open, look inside the exit path area. You should be able to see the jammed paper. It will typically be in one of three positions:

• Partially sticking out of the output tray. The leading edge of the paper has exited but the trailing edge is still caught in the exit rollers.
• Caught between the exit transport rollers. The paper is fully inside the finisher exit section and not visible from the output tray.
• Crumpled or folded inside the exit path. The paper has buckled due to a misfeed and is bunched up inside the transport area.

Step 4: Remove the Jammed Paper

Gently pull the jammed paper in the direction of travel, which is toward the output tray (outward and slightly downward on most models). Pull slowly and steadily. Do not yank the paper as this increases the risk of tearing.

If the paper is difficult to reach or tightly caught between rollers, look for a green or blue knob inside the finisher. Most Xerox finishers have a manual release knob that you can turn to advance the rollers and free the paper. Turn the knob in the direction indicated by the arrow label (usually clockwise).

If the paper tears during removal, you must find and remove all torn fragments. Even a small piece of paper left inside the exit path will cause an immediate repeat jam. Use a torch to inspect the roller area thoroughly.

Step 5: Check the Output Tray

Before closing the finisher, check the output tray itself. If the tray is overfull, the paper exiting the finisher has nowhere to go and will jam at the exit point. Remove the completed print jobs from the output tray.

Also check that the output tray is correctly seated. On some WorkCentre and AltaLink finishers, the output tray is removable for emptying. If it has not been fully reinserted after emptying, the paper exit sensor cannot detect that the tray is in position, which triggers the 077-900 error.

Step 6: Close the Finisher Cover and Confirm

Close the finisher front cover firmly until it clicks into place. The device should automatically detect that the cover is closed and begin clearing the error. On the touchscreen, the 077-900 or 077-901 error should disappear within 5 to 10 seconds.

If the error does not clear after closing the cover, open the cover again and check that no paper fragments remain. Also check that no other finisher covers or doors are open. Some finisher models have a secondary top cover or a rear access panel that must also be fully closed.

Step 7: Send a Test Print

Send a test print of at least 5 pages to confirm the jam has been fully cleared and the finisher is operating correctly. If possible, send a stapled print job as well, because stapling jobs route through additional finisher components that may also have been affected.

Why Does Xerox Error 077-900 Keep Happening?

If you are clearing this error once every few weeks, that is normal wear and tear for a busy London office running high-volume print jobs through a finisher. But if you are seeing 077-900 or 077-901 multiple times per day or even multiple times per week, there is an underlying cause that needs addressing.

Root Cause 1: Overfull Output Tray

This is the number one cause of repeat 077-900 errors in London offices. The finisher output tray has a maximum capacity (typically 500 to 1,000 sheets depending on the finisher model). When the tray is full, the next sheet exiting the finisher has nowhere to go and jams at the exit point. The fix is simple: empty the output tray more frequently, or set a lower tray capacity limit in the device settings to trigger an alert before the tray is completely full.

Root Cause 2: Worn Exit Rollers

The exit rollers in the finisher are rubber components that wear over time. As they wear, they lose grip and can no longer reliably push paper out of the finisher and into the output tray. This is especially common on devices printing more than 30,000 pages per month through the finisher. The rollers typically need replacement every 200,000 to 300,000 pages.

Signs of worn exit rollers include paper that consistently jams at the same point in the exit path, paper that exits the finisher at an angle or skewed, and paper that drops short of the output tray.

Root Cause 3: Paper Curl

Paper that curls excessively after passing through the fuser can cause problems in the finisher exit path. The curled edges catch on the exit guides and jam. This is common when printing on lightweight paper (under 80gsm), when printing in single-sided mode on paper designed for duplex, and in humid London office environments where paper absorbs moisture.

To reduce paper curl: use 80gsm paper or heavier for finisher jobs, store paper in sealed packaging until use, and enable the curl correction setting if your device has one (check the print driver under Paper/Output settings).

Root Cause 4: Incorrect Paper Size or Type Settings

If the paper size or type configured in the print driver does not match the actual paper loaded in the tray, the finisher may miscalculate the exit timing. For example, sending an A3 job when A4 is loaded will cause the finisher to expect a longer sheet, and the actual sheet will stop at the wrong position in the exit path.

Always verify that the tray paper size settings match the actual paper loaded. On VersaLink and AltaLink devices, you can configure the tray to auto-detect paper size, which reduces this risk.

Root Cause 5: Finisher Alignment Issue

If the finisher unit has been bumped, moved, or not correctly reconnected after maintenance, the physical alignment between the main device and the finisher can be off. This causes paper to enter the finisher at a slight angle, which compounds as the paper moves through the finisher and causes jams at the exit point. Ensure the finisher is firmly seated against the main device and all connection points are secure.

All 077-Series Xerox Error Codes at a Glance

While this guide focuses on 077-900 and 077-901, here is a quick reference for the entire 077-series finisher error family. If you are seeing a different 077 code, use this table to identify the specific issue.

For a complete guide to all 077-series errors including staple jams and booklet maker faults, see our dedicated finisher errors post linked at the bottom of this page.

Device-Specific Notes for 077-900 / 077-901

WorkCentre 7800 Series (7830, 7835, 7845, 7855)

On the WorkCentre 7800 series with the BR Finisher, the exit path jam is accessed by opening the front cover of the finisher and then lifting the green handle labelled area 4. This exposes the exit roller assembly. The green knob for manual roller advance is located directly behind this handle.

Common issue specific to this model: the output tray paper-full sensor can become stuck in the depressed position if a heavy stack of paper is left sitting on it for extended periods. When this happens, the device thinks the tray is always full and triggers 077-900 on every print job. Gently lift the sensor lever by hand to free it.

VersaLink B7000 / C7000 Series

VersaLink finishers use a different access method. The finisher front panel pulls forward (toward you) rather than swinging open. The exit path is visible at the top of the finisher when the panel is open. Paper typically jams between the top exit rollers and the output tray lip.

On VersaLink devices, the touchscreen provides animated step-by-step jam clearance instructions that are model-specific. Follow these on-screen instructions as they will match your exact finisher configuration.

AltaLink C8000 Series

AltaLink devices with the BR Finisher or Booklet Maker Finisher have the most complex exit path of any Xerox commercial device. The exit path routes through multiple roller sets depending on whether the job is being stapled, punched, folded, or delivered unfinished.

For 077-900 on AltaLink, always check both the main output tray and the top tray (offset catch tray). Paper can jam in the diverter gate between these two output points. Open the finisher top cover in addition to the front cover to check the diverter area.

Phaser 7800 Series

The Phaser 7800 with the optional Office Finisher has a simpler exit path than the MFP models. The finisher cover opens upward, and the exit rollers are directly visible. Jam clearance is straightforward on this model.

How to Prevent 077-900 / 077-901 From Recurring

Follow these preventive measures to significantly reduce the frequency of finisher exit path jams in your London office.

Daily Actions

• Empty the finisher output tray before it reaches 75% capacity. Do not wait for the tray-full warning.
• Check that the output tray is correctly seated after emptying. Push it in firmly until it clicks.
• Remove any damaged, folded, or crumpled pages from the output tray. These can obstruct the exit path for the next print job.

Weekly Actions

• Wipe the finisher exit rollers with a dry lint-free cloth. Paper dust builds up on the rubber surface and reduces grip.
• Check the finisher connection to the main device. Ensure the unit is firmly seated with no visible gap between the two.
• Run a finisher calibration from the touchscreen if your device supports it (Device > Tools > Troubleshooting > Finisher Calibration on AltaLink and VersaLink devices).

Monthly Actions

• Inspect the exit rollers for visible wear. If the rubber surface appears shiny, cracked, or flattened, replacement is due.
• Check the paper-full sensor in the output tray. Press it gently to confirm it moves freely up and down.
• Review the device fault history log via the EWS for 077-series error frequency. An increasing trend means roller replacement should be scheduled.

When to Call a Xerox Engineer for 077-900 / 077-901

While 077-900 and 077-901 are user-clearable in most cases, there are situations where a certified Xerox engineer is required.

• The error returns immediately after clearing, even with the output tray empty and no visible paper remaining inside the finisher. This indicates a faulty exit path sensor or a mechanical issue with the exit roller drive.
• You can hear grinding or unusual noise from the finisher exit area during printing. This suggests a worn gear, broken spring, or damaged roller bearing inside the exit assembly.
• The exit rollers are visibly worn (shiny, cracked, or hard) and need replacement. While the rollers themselves are technically user-replaceable on some models, the disassembly required to access them on BR and Booklet Maker finishers is complex and best handled by an engineer.
• The finisher has been bumped or moved and the alignment between the main device and finisher cannot be corrected by repositioning. An engineer can recalibrate the finisher connection.

For London offices, most Xerox service providers can replace finisher exit rollers on-site within a single visit. Typical cost for a finisher roller kit including labour is 80 to 180 GBP depending on the finisher model.

Frequently Asked Questions

Can I bypass the finisher to keep printing while 077-900 is showing?

Yes. Most Xerox devices allow you to bypass the finisher and print directly to the centre output tray (also called the pass-through tray). On the touchscreen, go to your print job settings and change the output destination from Finisher to Centre Tray. This will not staple or punch your documents, but it will let you continue printing while you resolve the finisher jam.

Is 077-900 covered under my Xerox service contract?

Paper jam clearance is typically not covered as a service call because it is classified as a user-clearable fault. However, if the jam is caused by a worn or failed component (exit rollers, sensors, drive gears), the component replacement is covered under most Xerox service contracts and managed print agreements. If you are clearing the same jam repeatedly, log a service call and reference the fault history showing the recurring 077-900 entries.

Can 077-900 damage my Xerox device?

A single 077-900 jam will not damage your device. However, repeatedly forcing jammed paper through the exit rollers (yanking rather than gently pulling) can scratch the roller surfaces and accelerate wear. Leaving torn paper fragments inside the finisher can also cause secondary jams in other areas of the device as fragments migrate through the paper path.

Why does 077-900 only happen with stapled jobs?

Stapled print sets are heavier and stiffer than single sheets. The stapled corner creates a thicker edge that can catch on the exit guides if the guides are slightly worn or misaligned. If 077-900 occurs only with stapled jobs, inspect the exit guides for burrs or damage, and check that the stapler is producing clean flat staples rather than bent or protruding ones.

Does paper weight affect 077-900 frequency?

Yes. Very lightweight paper (60gsm or less) is more likely to curl and buckle in the exit path. Very heavy paper or card (over 160gsm) may not bend easily enough to follow the exit path curve. For best results through the finisher, use paper between 75gsm and 120gsm. If you regularly print on heavy stock, consider routing those jobs to the centre tray instead of the finisher.