HP LaserJet P2015 Tray selection and Macs

Hi
We have a HP LaserJet P2015x. I've had trouble with it from Day 1 as it doesn't have a US Letter / A4 override option and we use A4 paper, but the odd user prints US docs without knowing it. I made some Print Presets for the users which applies the A4 scaling at the Mac end which works when the users remember to select the Preset.
In the last few weeks the printer stopped acknowlodging Tray / Media selections made in the Printer settings tabs (Mac 10.5.7 and Mac 10.5.8) I am not sure what was updated, reset, changed but after many hours re-installing drivers, changing driver, using other drivers, resetting the print system, cold reseting the printer etc... I still couldn't get it to print to our Letterhead Tray. Tray 2, set as A4, Letterhead. Regardless of the Paper Feed or Finishing > Media Type settings I made in the Driver it just kept printing from Tray 3, A4 Plain. (or would prompt for "Please load, Tray 2, A4 Plain if both Tray 2 and 3 were set as A4)
Somehow during all of this I noticed the *"Fit to Page"* option in the Driver tab for the Printer. I had it set to "Nearest Size and Scale" I changed it to *"Prompt User"* and magically it would now actually print from Tray 2, Letterhead when I made the Media Type change to "Letterhead". I have no idea why this fixed it but I made the change on 4 other Mac's and they can all now print to both trays normally again.
Hopefully this helps someone else out!!
Matt

So, I cranked up my old PowerBook G4 (OS 10.4.11) which has the older driver for the P2015dn and the problem remains.
I have made some progress: If I want to print with paper feed from Tray 1, I pull Tray 2 out a few inches, load the paper in Tray 1, start the print job, and the yellow Attention LED flashes indicating an error. Note that the Paper Out light does NOT come on. So I press the Go button, the Attention LED goes out, and the print job completes using the forms in Tray 1 as desired.
So I'm thinking now, What Error condition? and why does clearing it make it print?
Certainly seems like a hardware problem to me as this is NOT the way the printer is supposed to work as documenetd in the User Guide.

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