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Was the image captured on the smallest possbile drive? Are you using multicast option in your OSD script? Have you test your OSD script on previous machine that you were successfully deployed the image? Does your osd log show anyother other error?
We captured the image from 80gb and deploy 80gb,160gb. The use multicast domain discovery is selected. We have test client machine that deploy properly and they fail. The log file shows this,
"10-0-3-52","ERR_Fail",-1,0:00:02,7/20/2011 2:33:16 PM,7/20/2011 2:33:18 PM,"ldrun sdclient /f /o /dest="C:\sysprep\sysprep.inf" /p="http://10.0.0.70/landesk/files/Base62011.inf", STATUS"
; "Job Complete","0 Done","1 Failed","0 Off","0 Unknown"
That message indicates you were using a 160GB partition when capturing. If you still have the original disk/hardware you captured from I would follow these steps:
1 - Deploy to that same hardware (should fit)
2 - Before it can reboot into Windows and require you to re-sysprep go back into WinPE
3 - Run Diskpart, then select volume 1
4 - While in Diskpart run shrink querymax. If the result says it can shrink a lot (100ish GB) type shrink
5 - If result of shrink querymax is low (like only a few MB) run "select volume 2" and then try step 4 again
6 - If the partition shrink works recapture and you should be good to go. If it fails, let me know because it usually means you need to defragment and move some data to the front of the partition. (We can use Ultimate Defrag Mini to fix that)
Let me know if this helps. It will essentially shrink the partition to the smallest possible size for the amount of data you are holding, making it easier to deploy to other devices.