Xerox “016-747” — Tray size detection error (paper size mismatch)
Joe B.
Reviewed for technical accuracy
Specialities: Xerox VersaLink/AltaLink, tray sensors & paper guides, paper size mismatch, DADF/bypass tray setup
Xerox 016-747 paper size mismatch — tray size sensor, auto-sensing guides, dedicated vs fully adjustable trays
Technician
• Model family (VersaLink / AltaLink / WorkCentre) and which tray throws the error (Tray 1/2/3 or Bypass)?
• Is that tray set to Fully Adjustable or Dedicated size in the device settings?
• Paper actually loaded (A4/Letter/Legal/Custom) and paper type (Plain/Heavy/Labels)?
• Do the paper guides click firmly to the size marks, or is there play?
• Does the same job print from another tray or only fails here?
Technician
Plan: 1) Re-seat guides so the auto-sensor reports A4 exactly. 2) Confirm tray mode (Dedicated vs Fully Adjustable). 3) Match driver job ticket (size/type) to tray settings. 4) If needed, clean/check the tray size sensor and update firmware.
Technician
• On the C605 panel: Device → Trays → select Tray 2 → set Paper Size = A4, Type = Plain. If there’s a Tray Mode, choose Dedicated only if you always keep A4 there; otherwise choose Fully Adjustable so the printer asks to confirm when you reload.
• Reopen the tray, slide guides firmly to the molded A4 marks until they click. Auto-sensing uses those positions to detect size.
Step 2 — Align the job ticket in Windows/macOS
In the Xerox V4/Global driver, set Paper/Output → Paper = A4, Source = Tray 2, Type = Plain. If the driver requests “Auto” or Letter while the tray is Dedicated to A4, the controller flags a size mismatch.
Technician
• Guide play: with paper removed, gently wiggle side & rear guides. If there’s slack and they don’t hold the detent, the sensor reads a between-sizes state → mismatch.
• Stack height: overfilled or curled media can lift the stack and confuse the sensor. Load to the max line only, fan the ream.
• Paper type: if Tray 2 is Dedicated to Plain and you feed Labels/Heavy, the controller can block with a mismatch. Match type as well as size.
• Bypass/Known-good test: print the same job from Bypass or Tray 1. If it succeeds, Tray 2 hardware/settings are the issue; if it fails, the driver ticket is wrong.
Technician
1) Temporarily set Tray 2 to Fully Adjustable. Open/close the tray — the popup should ask to Confirm paper Size/Type/Color. Choose A4 • Plain • White and save. This forces the controller to refresh the tray’s profile.
2) Clean the size sensor/flags: power off, remove Tray 2, inspect along the side and rear for plastic flags & optical sensors. Blow out dust; wipe with a dry, lint-free cloth (no liquids). Reinsert tray and test.
If the popup doesn’t appear in Fully Adjustable mode, the switch or sensor isn’t moving — that’s when a technician should replace the guide assembly.
Technician
• Guides are tight with no play; replace worn trays/guides if needed.
• Driver defaults for users enforce A4 • Plain and Source = Tray 2 (use a shared queue policy).
• Disable application overrides like “Fit to Letter” that silently request Letter and trigger paper size mismatch.
Keeping it in Fully Adjustable is fine — operators confirm size on reload and you avoid 016-747.
Technician
• Bypass tray: always select the exact Size/Type on the popup (A4/Letter/Envelope, Plain/Heavy). If you skip it, jobs can halt with paper type/size mismatch.
After DSM/firmware updates on NAS/print servers, re-check driver defaults so apps don’t override to Letter.
Technician
Technician
Quick answer: the accepted fix
Accepted fix for Xerox 016-747 tray size detection: set the tray to Fully Adjustable and Confirm Size/Type on reload, reseat paper guides to the exact A4/Letter detents, match the driver’s size & type to the tray, then clean the tray size sensor. Use Dedicated mode only if size never changes.
Why 016-747 appears — auto-sensing guides, dedicated trays & driver mismatch
The controller compares the tray’s auto-sensed size (from paper guide switches) with the job’s requested size/type. If guides are off the detent, the tray is set to the wrong mode (Dedicated vs Fully Adjustable), or the driver asks for Letter while A4 is loaded, you get a paper size mismatch. Realigning guides, confirming size on the popup, and enforcing driver defaults eliminates the fault.
How to verify tray size detection is fixed
• Open/close the tray — ensure the Confirm Size/Type popup appears in Fully Adjustable mode and shows the correct A4/Letter.
• Print one job from each tray (Tray 1/2 & Bypass) using Plain media. No “size mismatch” prompts should appear.
• In the driver, switch between A4 and Letter; jobs should route to the matching tray without 016-747.
• For scans/copies, set DADF guides tight and clean feeder sensors so originals detect properly.
Tray size detection — quick troubleshooting tips
Most cases are loose guides, wrong tray mode, or driver paper size overrides.
Quick path: reseat paper guides, set tray to Fully Adjustable, confirm Size/Type on reload, align driver defaults (A4/Letter • Plain), and clean tray size sensors. For strict media control, use Dedicated trays only with perfect guide alignment and enforced driver policies.
Disclaimer: This information is AI-generated and intended for general guidance only. For advice specific to your environment, please consult a verified expert on Whizz-Tech before making decisions.
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FAQ
What does Xerox 016-747 tray size detection error mean?
016-747 indicates a paper size mismatch — the tray’s auto-sensed size/type doesn’t match the job request. Reseat paper guides, confirm Size/Type on the tray popup, and align driver defaults.
Should I use Dedicated or Fully Adjustable trays?
Use Fully Adjustable if the tray’s size changes — you’ll confirm Size/Type after reload. Use Dedicated only when the size never changes and guides are tight; otherwise you’ll trigger mismatches.
Why does Bypass/DADF show “size not detected”?
Bypass requires manual selection of exact Size/Type on load. For the DADF, set guides snug and clean sensors. Dust and loose guides cause incorrect size detection for copies/scans.
Sources
- Xerox — Modify the Paper Tray Settings (size/type)
- Xerox — Resolving Dedicated Tray Size Mismatch Error
- Xerox — DADF is Not Detecting the Paper Size (guides/sensors)
Filed under: Paper handling & media (jams/feeds/duplex)
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