asked May 5, 2011 at 12:10pm
Hp HP LaserJet 4240

HP LaserJet 4240 Paper Path Problem...

We have an HP LJ 4240N printer that as decided to be picky all of a sudden.

When you print, it will print the first page and then pause, displaying "Clearing Paper Path" message and then flashing the Attention light and displaying "41.3 Unexpected Size in Tray 2 Error".

You can clear the error by removing the tray and reinserting it and hittign the check button... it will then print another page and repeat the error.

Here's what I've done:

- Cleaned the printer out top to bottom

- Replaced rollers

- Replaced the fuser

- Tried a different paper tray

- Tried different paper

Anyone have any guidance or suggestions here? I'm fresh out..

Thanks in advance!
The error is exactly what it says. The paper trips a number of sensors throughout the printer. It has to trip them at a precise time or the printer will give either a paper jam or unexpected size error. For instance, if the tray is set at the legal stop, but a letter size paper goes through, then it will be an unexpected size because the tail end will have released the sensor early. First thing to do is to print a config page from the printer menu. It will tell you what size the printer thinks the tray is set for. If it matches the size you are telling it to print, then we continue from there.
by moe on May 5, 2011 at 12:28pm Add comment
Yes, I considered that... but in the printer settings and the tray tabs. And it will always print the first page successfully. The tray is set correctly (and I've tried a different tray to rule out a problem with the tray) and the paper is in correctly.

- bsarte
The fact that it displays the "Clearing Paper Path" message means the printer still perceives that a piece of paper is in there after that first page goes through. Does a second blank page come out of the printer. You need to provide all the details as we can't see or test the printer.
by moe on May 5, 2011 at 1:29pm Add comment
I will ask one question which you did not answer for Moe. Did you print a config page. Yes or No. If yes what paper size does the sheet show for tray 2. One sensor that is overlooked is the sensor flag below the registration assembly. It sometimes gets gummed up and then sticks in the down position. Usually loosing the registration assembly screws, gently lifting up a bit and blowing out with a can of compress air solves the problem. This would only be the case if the config page paper setting for tray 2 matches the size the tray is set for.
by dmzcompute on May 5, 2011 at 3:15pm Add comment
DMZ -- Yes, I have printed a config page it shows "TRAY 2 Size: Letter" which is correct.

Thank you for the suggestion about the registration assembly... as soon as I find out where that is -- I'm going to do that and see if it helps!
by bsarte on May 6, 2011 at 5:15am Add comment
If you take out the toner cartridge and look straight down, that's the registration assembly.
by moe on May 6, 2011 at 7:50am Add comment
Update: taking the registration assembly apart and putting it back together fixed the issue. Must have been something sticking in that assembly.

Thanks DMZ!
by bsarte on May 6, 2011 at 7:52am Add comment
I am currently having this issue, and have tried all of the above; trays, rollers, fuser, registration assembly, formatter, dc controller, power supply, toner, checking sensors. I have also checked the tray settings themselves, and tried an engine test. The engine test works fine but when trying either a config page or anything else printing it comes up with the clearing paper path and then the unexpected page size error. Any other suggestions?
by unknown on Dec 27, 2012 at 12:52pm Add comment
Have you tried printing from the MF tray?
by moe on Dec 27, 2012 at 8:11pm Add comment
"...the MF tray?"

uh Moe, there's no need for profanity.

- eric111
did you try using compressed air to blow out the three sensors under the registration assy ?
by laserphil on Dec 28, 2012 at 9:05am Add comment