Not sure if this is your specific problem, but you need to make sure that for size option you choose “Actual Size” and not “Fit” or Shrink or Scale in your printer properties.
In addition to selecting “Actual Size” under print properties in Adobe Reader (as mentioned above), also make sure that the left and the top margins are set correctly for your printer (as I found out, it varies based on the specific printer being used). You may need to run a few test claims.
If you are on Linux, the xpdf program does better than okular for this in my experience. Also check the Administration | Globals | Miscellaneous | Print Command
We have a Windows based system using Firefox. I played with the print settings. I went to the properties on my printer and removed the page “scaling.” This is working. Evidently when Windows or printer setting try to “shrink to fit” or “Fit to paper size” it messes everything up.
For the occasional times that a paper claim must be submitted and when it is impossible to adjust the margins either from the PDF reader or from the printer, here is freeware which does not leave a watermark: PDFill Free PDF Tools.
It can be downloaded from C|NET and used for multiple .pdf files. It was scanned with anti-virus before installation.
Use Tool #4. Crop the file in the direction in which it needs to move; i.e., if the form needs to go down 1/8", crop the bottom margin by 1/8". Sometimes it is necessary to clear the field and type in 0.125" to get the crop; cannot just type .125 between the existing zero and inch symbol.
Only the paid versions of the PDF readers have this utility, so don’t spend time trying to figure out how to move the margins with the free readers. It works with Adobe and Foxit.