When I use paper from the stack bypass, especially 'heavy' paper (160 gsm) the first 3 or so pages are misregistered... the colours don't line up, resulting in blurry images or (colour) text. It sometimes happens from the drawers as well, but every time from the stack bypass, doesn't matter what sort of paper. Have been using predominantly Mondi colour copy 160 gsm on Canon irC3220. Wasting a lot of paper. Anyone have any ideas?

Hi Nigel
There is currently rationing of periods (. .), so I removed them from your question and tidied it up a bit :>D I also aids readability and the ability of search engines to find your question.

This is a very obscure printer and there doesn't seem to be any data on it. I would contact someone in the service department. There must be an error on the top cover if it saying that. Look for an optical sensor and clean it, or look for something on the lid that presses into a hole. If it is an erroneous message, open all the covers, doors and the bypass door at the back and look for a tiny piece of torn paper. It's an office machine, staff get a jam, they drag the paper out and then wonder why it doesn't work afterwards, so they say nothing thinking they broke it. They left a piece of paper inside.

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Issue
While printing, the printer paper is torn, ripped, wrinkled, or damaged.Solution Follow these steps in the order presented to resolve the issue.Step one: Remove all paper from the input and output trays Remove all paper from the input and output trays on the product.Step Two: Check the paper path for obstructions Press the Power ( ) button to turn off the product. Verify the input tray is empty, and then check for paper jams, bits of paper, and other obstructions, gently removing any obstructions.Lift the top door or the front cover, depending on the product, to access the print carriage, and then check for any obstructions in the paper path.Gently remove any paper or other obstructions from the paper path you might find, and then close the print carriage access door.Open the rear access door.Gently remove any paper or other obstructions from the paper path.Check the spring-loaded rear access door rollers to verify that they are clean and can be rolled.check the paper rollers inside the rear access and verify that the rollers are clean and roll upwards.Check the star wheel assembly inside the printer on the output side of the carriage. Verify that it is in good condition and clear of paper bits or other obstructions. NOTE:The star wheel assembly is located inside the printer on the output side of the carriage. The star wheel assembly is a set of small, star-shaped wheels on top and rubber rollers on the bottom. The assembly grips the printed side of the paper, and moves the paper to the output tray after printing.Replace the rear access door and verify that the rollers on the door and the rollers inside the rear access of the product are "matched up" with each other.Press the power button to turn on the product.Step Three: Check the paper type Verify that only recommended paper is being used for printing. The recommended paper types and weights for most HP printers include: Plain paper, 20 to 24 lb (75 to 90 gsm) Legal size paper, 20 to 24 lb (75 to 90 gsm) Card stock, up to a maximum of 110 lb (200 gsm) Envelopes, 20 to 24 lb (75 to 90 gsm) Photo paper, 145 lb (236 gsm) NOTE:Supported paper weights and types vary by product. Check the Specifications sheet for your product for more information.Step Four: Make sure that the paper is loaded correctly Gather a stack of plain, white paper and load it in the product's input tray.Use only one type of paper in the stack.Use 10 to 25 sheets of paper in the stack.Fan the stack of paper to make sure that the sheets do not stick together. Tap the stack of paper against a hard, flat surface, such as a table top, to make the edges even.Insert the stack of paper into the input tray.make sure that the stack of paper is flat in the input tray. Verify the right side of the stack of paper touches the right side of the input tray and that the stack is pushed completely into the tray.Position the paper guides firmly against the sides of the paper stack without bending the paper.Step Five: Test the All-in-One Follow these steps to print a self-test page. If the page prints successfully, the product is functioning correctly.Press the Setup button on the printer.Depending on what product you have, perform one of the following:Press the arrow key to select Print Report and then press OK.Press the arrow key to select Self Test eport and press OK.A test page prints.If the test page prints without damaging the paper, you do not need to take any other action.If the test page is damaged during printing, proceed to the next step.NOTE:For printers which do not have a Setup button, check the product documentation to find out how to print a self test page.Step Six: Contact HP If you have completed all the steps listed above and are still experiencing a problem, the rear access door or the star wheel assembly is likely damaged. To replace the rear access door, contact HP. If the star wheel assembly is damaged, replace the product.Cause There are several possible causes: Bits of paper might be obstructing the paper path and need to be cleared.Unsupported paper types and sizes might catch and tear in the printer mechanism while printing.Paper pushed too far into the input tray when it is loaded, might feed into the printer incorrectly, causing the paper to tear.Paper stacks loaded into the input tray with too many or too few sheets of paper, might feed into the printer incorrectly, causing the paper to tear.Paper stacks that are not properly stacked when loaded into the input tray, might feed into the printer incorrectly, causing the paper to tear.The rollers on the rear access door and inside the product's rear access might not be clean, in good condition or freely rolling.the star wheel assembly might be obstructed or have damaged or missing parts, causing the paper to tear.The rear access door might be damaged.The wheels on the star wheel assembly might be damaged.

It sounds likea problem with your paper stock. Check the following to make sure you are using a paper type that is compatible with your printer.

Recommended paper

Plain Paper: Xerox Premier 80 gsm
Xerox Business 80 gsm
Mode DATACOPY 80 gsm
IGEPA X-Press 80 gsm
Recycled paper: Xerox Recycled Supreme
Transparency: 3M CG 3300
Labels: Avery laser label L7163

??  Before you buy a large amount of paper, please test some to make sure that the paper is suitable.
??  Use paper that is made for plain-paper copying.
??  Use paper that is 75 to 90 gsm.
??  Use neutral paper. Do not use acidic or alkaline paper.
??  Use long-grain paper.
??  Use paper with a moisture content of approximately 5%.

Caution
Do not use ink jet paper. It may cause a paper jam and damage your MFC.

Choosing acceptable paper

It is recommended that you test paper (especially special sizes and types of paper) on the MFC before purchasing large quantities.

??  Avoid feeding label sheets that are partly used or your MFC will be damaged.
??  Avoid using coated paper, such as vinyl coated paper.
??  Avoid using preprinted or highly textured paper, or paper with an embossed letterhead. For optimum printing, use a recommended type of paper, especially for plain paper and transparencies. For more information on paper specifications, call your nearest authorized sales representative or the place where you purchased your MFC.
??  Use labels or transparencies that are designed for use in laser printers.
??  For the best print quality, we recommend using long-grained paper.
??  If you are using special paper and the paper has problems feeding from the paper tray, try again using the manual feed tray or Multi-purpose tray.
??  You can use recycled paper in this MFC.

The output quality depends on the paper type and paper brand. Visit http://solutions.brother.com and check the latest recommendations for paper that can be used with the MFC-8840D.

check if piece of paper is stuck in the over of your printer  
try printing in a heavy paper (160+ grams) 

Set the bypass guides for the largest size paper in the document. Bypass feeders are dumb, they don't care what size the paper is.

That is the way duplexing works. Both sides of the page are read into memory and then the second page prints followed by the first page after the paper turns around.

Turn you paper stack over so the the 2nd. page prints correctly on the page and the first page should be fine. If it does not, please let me know and we can take some steps to look at the data going to the printer.

Don

Are you using the bypass tray for the second run? If so, of course you have a problem with the bypass paper path. As you might know, the workaround is to place the printed page face down on top of the paper stack in the input tray. . I would be amazed that if you tried to run it this way (page on stack) that the machine would cough it up. That would amaze me. Try running sparcely printed stuff through, stuff printed on only one side of the page, then the other, then the center, etc. Could be that there is some sensor in there that doesn't like black toner marks just to see what is going on. Then go from there by asking online with that info. . Good luck.

1-did you change to bypass instead of trays in the menu?
2-the sensor (black lever in the bypass that triggers the sensor) is missing or bad

you can select for tray (letter size ) as default in paper settings
the stack bypass paper sensor may be broken and is active all the time

Hi it would appear that the paper is too heavy for the machine check the manual as it will have the spec on what paper can be used and also how heavy the paper could be.

Sorry I cannot be anymore help but try using a paper that is about 10-20 gsm lighter.

Thanks J