Hello, let me start by saying I totally understand your frustration! I'd been dealing with this issue for weeks, I tried so many things that I wouldn't be able to tell you what exactly worked for me, but I will share with you the last few steps I took before I got my bypass tray to finally work again:
1. Make SURE that the tray settings on your computer match the tray settings on the printer monitor.. if your monitor is set to "lightweight card stock" and the settings on your computer are set to "card stock" it will NOT print.
2. I removed and re-inserted the fuser, let the fuser cool down for 5 minutes or so before re-inserting.. I did not replace or buy a new fuser.. simply removed it for a few minutes.. let it cool down and re-inserted it. Here is the tutorial on how to remove it:
I hope this helps.
I guess this issue has never been fixed. It still happening. A LOT in 2017. Funny you don't have this problem so much with cheap printers.
Thank you for using the Xerox forum.
I suggest that you review
Solutions for : How To Modify the Paper Size, Type, or Color
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I am having quite a bit of difficulty with tray 1 on my phaser 7800DN. I have yet to print a single sheet from tray 1 as I continue to get the paper size jam error, and the resources required prompt. It prompts me for plain white paper, which it is full of.
All of the resources I have found suggest removing the paper and replacing it with a fresh out of the package stack, and double checking the tray size settings, but as far as I can tell, everything is correct - it simply won't take the paper!
I am growing frustrated. Any help would be greatly, greatly appreciated!