Constantly getting a size mismatch error (41.03.A2)error in the middle of printing jobs

[YDIPurchasing]

Our Color Laserjet MFP M577 started giving us a size mismatch error for paper tray 2.  We checked the guides and they are locked into place for the correct size.  We have checked the settings in the printer for that tray and have restarted the printer.  We can open the tray and tell the printer the correct size and it will print a couple of sheets and then display the error message again.  We are not able to print more that a couple of pages at a time.  When we open drawer two it appears that it is working to lift the next page but did not complete the process.  Needless to say this is frustrating on a high volume machine.  We have looket at the troubleshooting and have done everything suggested.  Looking for more help.

[Alex-TATS]

Hi YDIPurchasing,

Please follow the steps below, in that order, doing and checking exactly as described:

41.03.YZ Unexpected size in tray <X>

The printer detected a different paper size than expected.

Y = Type, Z = Tray

• Y = 0 Size mismatch. Detected paper is longer or shorter than expected.
• Y = A Size mismatch. Detected paper too long.
• Y = B Size mismatch. Detected paper too short.
• Y = C Size mismatch. Inter-page gap error.
• Y = D Size mismatch. Detected paper narrower than expected.
• Y = E Size mismatch. Detected paper wider than expected.

• Z = D Source is the duplexer.
• Z = E Source is the envelope feeder.
• Z = 1 Source is Tray 1.
• Z = 2 Source is Tray 2.
• Z = 3 Source is Tray 3.
• Z = 4 Source is Tray 4.
• Z = 5 Source is Tray 5.

Recommended action

1. Touch OK to use another tray.
2. Print a configuration page to verify the size and type the trays are set to.
3. Ensure that the tray width and length guides are set to the correct paper size being installed into the tray and that the tray is not over filled above the fill mark or over the tab on the tray.
4. Verify that the error is not occurring as a result of an unexpected paper size trigger caused by a multi-page feed.
5. If the paper is jammed, ensure it is completely removed. If paper has been ripped during removal and paper is stuck in the feed roller, spin the rollers down, which feeds the jammed paper up for easier removal.
   Figure : Feed rollers

   
6. Verify that the toner cartridge and the transfer roller are seated correctly.
7. Use the Tray/Bin manual sensor test to verify that the cassette paper switch is functioning correctly.
8. Check paper path sensors SR6 and SR9 for correct operation and that they do not stick at all. Replace any damaged sensor or assembly.
9. Check paper width sensors SR13 and SR14 for correct operation and that they do not stick at all. Replace any damaged sensor or assembly.
10. Reconnect the connectors for the paper sensor, the intermediate-transfer belt, and the DC controller PCA.

       NOTE:

    • SR6 Top Sensor connects to DCC on J118.
    • SR9 fuser delivery sensor connects to fuser PCA on J2603 then to interconnect J50 then to DCC on J116.
    • SR13 and SR14 paper width sensors connect to DCC on J118.

11. Test the registration assembly motor and clutch. If they do not function correctly, replace the registration assembly.
    Part number:

    Description	HP Part Number
    Registration assembly (M552dn, M553dn, M553x, M577)	RM2-0018-000CN
    Registration assembly (M553n)	RM2-0093-000CN

12. If the error persists, replace the tray lifter assembly.

I hope this will help you,

Cheers!