"The job separator tray is full." message

[blackcat4866]

I think I know what happened, just looking for confirmation;

Firstly it's a KM-4052ci with bridge and DF-7120 finisher. The enduser recently installed a new driver and, not unusual, did not designate which accessories were installed. Since the driver was unaware of a finisher, all the print outputs go to the upper engine tray. Up until now all copy, fax and report outputs went to the finisher.

So I start testing sensors in U031 and I discover that the flags for the upper exit and the job separator full sensor are ... well not there, along with all the paraphernalia that go with them. Only the photointerrupters themselves are still there, lonely, no flags to keep them company.

I suspect that on some other model it was necessary for the setup guy to remove to remove a sensor flag, so he did it here too. I checked the setup procedure and there is no mention of removing sensor flags, so I assume they're still supposed to be there.

I don't see any setups, so I don't really know what's involved. Does that sound plausible? =^..^=

[Tonerkiller]

Did someone put in the new style exit unit? If so check the connector for the exit unit. We had a couple that came back a couple days later for a jam or jamming. The tech just had replug in the connector for the exit unit properly.

[blackcat4866]

No, this is the first service this machine has seen, ~6 months. I just can't imagine where those damn sensor flags went. =^..^=

[Santander]

No, this is the first service this machine has seen, ~6 months. I just can't imagine where those damn sensor flags went. =^..^=

Reminds me of a call I had a couple of weeks ago on an old 6030, the jam code was for the paper conveying section on on the right side of the unit. Opened the door and found one sensor with no flag [an integral part of the sensor] and one sensor and flag completely gone!! Quizzically, how do you rip out two sensors when if you open the door the jammed paper falls out of the unit??

[blackcat4866]

Reminds me of a call I had a couple of weeks ago on an old 6030, the jam code was for the paper conveying section on on the right side of the unit. Opened the door and found one sensor with no flag [an integral part of the sensor] and one sensor and flag completely gone!! Quizzically, how do you rip out two sensors when if you open the door the jammed paper falls out of the unit??

That was surprisingly common. Kyocera came out with a modification to screw down the vertical path sensors so they weren't left dangling from the wires. The problem was the the customer felt the need to smash the sensors that were screwed down. After modifying two machines, I went back and re-installed the sensors that pop out and dangle from the wires. You can put those back in, essentially undamaged. =^..^=

[dt5405]

I know this is an old thread but wanted to add i've seen this caused by a user trying to send a duplex job to a cassette set to legal/cardstock.