Konica Minolta Bizhub 4020 User manual

SERVICE MANUAL
2015.12
Ver. 1.1

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Trademarks
KONICA MINOLTA and KONICA MINOLTA logo are trademarks or resisted trademarks of KONICA
MINOLTA, INC.
bizhub is trademarks or resisted trademarks of KONICA MINOLTA, INC.
Mac and the Mac logo are trademarks of Apple Inc., registered in the U.S. and other countries.
PCL® is a registered trademark of the Hewlett-Packard Company. PCL is Hewlett-Packard Company’s
designation of a set of printer commands (language) and functions included in its printer products. This
printer is intended to be compatible with the PCL language. This means the printer recognizes PCL
commands used in various application programs, and that the printer emulates the functions
corresponding to the commands.
All other trademarks are the property of their respective owners.
© 2013 KONICA MINOLTA, INC.
All rights reserved.

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Contents
1. Notices and safety information ....................................................................................................... 16
1.1 Laser notices............................................................................................................................ 16
1.1.1 Laser notice ...................................................................................................................... 16
1.1.2 Laser-Hinweis................................................................................................................... 16
1.1.3 Avis relatif à l'utilisation du laser....................................................................................... 16
1.1.4 Avvertenze sui prodotti laser ............................................................................................ 16
1.1.5 Aviso de láser ................................................................................................................... 16
1.1.6 Aviso sobre laser .............................................................................................................. 17
1.1.7 Laserinformatie................................................................................................................. 17
1.1.8 Lasererklæring.................................................................................................................. 17
1.1.9 Laserilmoitus..................................................................................................................... 17
1.1.10 Lasermeddelande............................................................................................................. 17
1.1.11 Lasermerknad................................................................................................................... 18
1.1.12 Avís sobre el làser ............................................................................................................ 18
1.1.13 レーザーに関する通知 .................................................................................................. 18
1.1.14 레이저 관련 공지 ......................................................................................................... 18
1.1.15 激光注意事项................................................................................................................ 18
1.1.16 雷射聲明........................................................................................................................ 19
1.2 Safety ....................................................................................................................................... 19
1.2.1 Safety information............................................................................................................. 19
1.2.2 Consignes de sécurité...................................................................................................... 19
1.2.3 Norme di sicurezza........................................................................................................... 20
1.2.4 Sicherheitshinweise.......................................................................................................... 20
1.2.5 Pautas de Seguridad ........................................................................................................ 20
1.2.6 Informações de Segurança............................................................................................... 21
1.2.7 Informació de Seguretat ................................................................................................... 21
1.2.8 안전 사항.......................................................................................................................... 21
1.2.9 安全信息............................................................................................................................ 22
2. Preface............................................................................................................................................ 23
2.1 Service manual conventions .................................................................................................... 23
2.2 Change History......................................................................................................................... 24

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3. General information ........................................................................................................................ 25
3.1 Understanding the control panel and menus (bizhub 3320) .................................................... 25
3.1.1 Using the printer control panel.......................................................................................... 25
3.1.2 Understanding the colors of the indicator and Sleep button lights ................................... 26
3.2 Understanding the control panel and menus (bizhub 4020) .................................................... 27
3.2.1 Using the printer control panel.......................................................................................... 27
3.2.2 Understanding the colors of the indicator and Sleep button lights ................................... 28
3.2.3 Understanding the home screen ...................................................................................... 29
3.2.4 Using the touch-screen buttons........................................................................................ 30
3.3 Menus list ................................................................................................................................. 32
3.4 Media guidelines ...................................................................................................................... 33
3.4.1 Paper guidelines............................................................................................................... 33
3.4.2 Using recycled paper and other office papers.................................................................. 35
3.4.3 Using specialty media....................................................................................................... 36
3.4.4 Supported paper sizes, types, and weights...................................................................... 38
3.5 Data security notice.................................................................................................................. 42
3.6 Tools required for service......................................................................................................... 42
4. Diagnostic information .................................................................................................................... 43
4.1 Troubleshooting overview ........................................................................................................ 43
4.1.1 Performing the initial troubleshooting check..................................................................... 43
4.1.2 Power-on Reset (POR) sequence.................................................................................... 43
4.1.3 Using Safe Mode .............................................................................................................. 44
4.2 Fixing print quality issues ......................................................................................................... 45
4.2.1 Initial print quality check.................................................................................................... 45
4.2.2 Gray background or toner fog on prints............................................................................ 46
4.2.3 Repeating defects............................................................................................................. 47
4.2.4 Printer is printing blank pages .......................................................................................... 47
4.2.5 Printer is printing solid black pages.................................................................................. 48
4.2.6 Shadow images appear on prints..................................................................................... 49
4.2.7 Skewed print..................................................................................................................... 50
4.2.8 Streaked horizontal or vertical lines appear on prints ...................................................... 53
4.2.9 Toner rubs off ................................................................................................................... 54
4.2.10 Toner specks appear on prints......................................................................................... 55

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4.3 Paper jams ............................................................................................................................... 56
4.3.1 Avoiding jams ................................................................................................................... 56
4.3.2 Understanding jam messages and locations.................................................................... 58
4.3.3 200 paper jams................................................................................................................. 59
4.3.4 201 paper jams................................................................................................................. 68
4.3.5 202 paper jams................................................................................................................. 70
4.3.6 23y paper jams ................................................................................................................. 74
4.3.7 241 paper jams................................................................................................................. 77
4.3.8 242-244 paper jams.......................................................................................................... 81
4.3.9 250 paper jams................................................................................................................. 88
4.3.10 28y paper jams ................................................................................................................. 91
4.3.11 29y paper jams ................................................................................................................. 94
4.4 Understanding printer messages ............................................................................................. 96
4.4.1 Cartridge low [88.xy]......................................................................................................... 96
4.4.2 Cartridge nearly low [88.xy].............................................................................................. 96
4.4.3 Cartridge very low, [x] estimated pages remain [88.xy].................................................... 96
4.4.4 Change [paper source] to [custom string] load [paper orientation]................................... 96
4.4.5 Change [paper source] to [custom type name] load [orientation]..................................... 96
4.4.6 Change [paper source] to [paper size] load [orientation].................................................. 96
4.4.7 Change [paper source] to [paper type] [paper size] load [orientation] ............................. 97
4.4.8 Close flatbed cover and load originals if restarting job [2yy.xx]........................................ 97
4.4.9 Close door......................................................................................................................... 97
4.4.10 Configuration change, some held jobs were not restored [57]......................................... 97
4.4.11 Complex page, some data may not have printed [39]...................................................... 97
4.4.12 Defective flash detected [51] ............................................................................................ 98
4.4.13 Disk must be formatted for use in this device................................................................... 98
4.4.14 Error reading USB drive. Remove USB............................................................................ 98
4.4.15 Error reading USB hub. Remove hub............................................................................... 98
4.4.16 Fax partition inoperative. Contact system administrator. ................................................. 98
4.4.17 Fax server 'To Format' not set up. Contact system administrator.................................... 98
4.4.18 Fax Station Name not set up. Contact system administrator. .......................................... 98
4.4.19 Fax Station Number not set up. Contact system administrator........................................ 99
4.4.20 Imaging unit low [84.xy].................................................................................................... 99

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4.4.21 Imaging unit nearly low [84.xy] ......................................................................................... 99
4.4.22 Imaging unit very low, [x] estimated pages remain [84.xy]............................................... 99
4.4.23 Incorrect paper size, open [paper source] [34]................................................................. 99
4.4.24 Insufficient memory, some Held Jobs were deleted [37].................................................. 99
4.4.25 Insufficient memory, some held jobs will not be restored [37]........................................ 100
4.4.26 Insufficient memory for Flash Memory Defragment operation [37] ................................ 100
4.4.27 Insufficient memory to collate job [37]............................................................................ 100
4.4.28 Insufficient memory to support Resource Save feature [35] .......................................... 100
4.4.29 Load manual feeder with [custom string] [paper orientation].......................................... 100
4.4.30 Load manual feeder with [custom type name] [paper orientation].................................. 100
4.4.31 Load manual feeder with [paper size] [paper orientation] .............................................. 101
4.4.32 Load manual feeder with [paper type] [paper size] [paper orientation] .......................... 101
4.4.33 Load [paper source] with [custom string] [paper orientation].......................................... 101
4.4.34 Load [paper source] with [custom type name] [paper orientation].................................. 102
4.4.35 Load [paper source] with [paper size] [paper orientation] .............................................. 102
4.4.36 Load [paper source] with [paper type] [paper size] [paper orientation] .......................... 102
4.4.37 Maintenance kit low [80.xy]............................................................................................. 102
4.4.38 Maintenance kit nearly low [80.xy].................................................................................. 102
4.4.39 Maintenance kit very low, [x] estimated pages remain [80.xy]....................................... 103
4.4.40 Memory full [38] .............................................................................................................. 103
4.4.41 Memory full, cannot print faxes....................................................................................... 103
4.4.42 Memory full, cannot send faxes...................................................................................... 103
4.4.43 Network [x] software error [54]........................................................................................ 103
4.4.44 No analog phone line connected to modem, fax is disabled.......................................... 103
4.4.45 Non- Printer Manufacture [supply type], see User’s Guide [33.xy] ................................ 103
4.4.46 Not enough free space in flash memory for resources [52]............................................ 104
4.4.47 Printer had to restart. Last job may be incomplete......................................................... 104
4.4.48 Reinstall defective or unresponsive cartridge [31.xy]..................................................... 104
4.4.49 Reinstall missing or unresponsive cartridge [31.xy] ....................................................... 104
4.4.50 Remove paper from standard output bin........................................................................ 105
4.4.51 Replace all originals if restarting job............................................................................... 105
4.4.52 Replace cartridge, 0 estimated pages remain [88.xy] .................................................... 105
4.4.53 Replace cartridge, printer region mismatch [42.xy]........................................................ 105

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4.4.54 Replace defective imaging unit [31.xy]........................................................................... 106
4.4.55Replace jammed originals if restarting job...................................................................... 106
4.4.56 Replace imaging unit, 0 estimated pages remain [84.xy]............................................... 106
4.4.57 Replace maintenance kit, 0 estimated pages remain [80.xy]......................................... 106
4.4.58 Reinstall missing or unresponsive imaging unit [31.xy].................................................. 106
4.4.59 Replace unsupported cartridge [32.xy]........................................................................... 107
4.4.60 Replace unsupported imaging unit [32.xy] ..................................................................... 107
4.4.61 Restore held jobs?.......................................................................................................... 107
4.4.62 Scanner automatic feeder cover open............................................................................ 107
4.4.63 Scanner disabled by admin [840.01] .............................................................................. 107
4.4.64 Scanner disabled. Contact system administrator if problem persists. [840.02].............. 107
4.4.65 Scanner jam, remove all originals from the scanner [2yy.xx]......................................... 107
4.4.66 Scanner jam, remove jammed originals from the scanner [2yy.xx]................................ 107
4.4.67 Serial option [x] error [54] ............................................................................................... 108
4.4.68 SMTP server not set up. Contact system administrator................................................. 108
4.4.69 Some held jobs were not restored.................................................................................. 108
4.4.70 Standard network software error [54] ............................................................................. 108
4.4.71 Standard USB port disabled [56].................................................................................... 108
4.4.72 Supply needed to complete job ...................................................................................... 108
4.4.73 Too many flash options installed [58] ............................................................................. 109
4.4.74 Too many trays attached [58]......................................................................................... 109
4.4.75 Unformatted flash detected [53] ..................................................................................... 109
4.4.76 Weblink server not set up. Contact system administrator.............................................. 109
4.5 User attendance messages (0–99.99)................................................................................... 110
4.5.1 User attendance messages (0-99.99)............................................................................ 110
4.5.2 Toner cartridge smart chip contact service check.......................................................... 111
4.5.3 Imaging unit smart chip contact service check............................................................... 112
4.5.4 Toner smart chip compatibility service check................................................................. 112
4.5.5 Imaging chip compatibility service check........................................................................ 113
4.5.6 Media size mismatch service check ............................................................................... 113
4.5.7 Printer/cartridge mismatch service check....................................................................... 115
4.5.8 Flash full service check................................................................................................... 115
4.5.9 Maintenance kit service check........................................................................................ 116

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4.5.10 Insufficient memory service check.................................................................................. 116
4.5.11 Imaging unit low service check....................................................................................... 116
4.5.12 Toner cartridge low service check.................................................................................. 117
4.6 Printer hardware errors .......................................................................................................... 118
4.6.1 111 errors........................................................................................................................ 118
4.6.2 126 errors........................................................................................................................ 122
4.6.3 132 errors........................................................................................................................ 123
4.6.4 133 errors........................................................................................................................ 124
4.6.5 140 errors........................................................................................................................ 125
4.6.6 146 errors........................................................................................................................ 126
4.6.7 155 errors........................................................................................................................ 127
4.6.8 171 errors........................................................................................................................ 129
4.6.9 Procedure before starting the 9yy service checks.......................................................... 131
4.6.10 900 errors........................................................................................................................ 132
4.6.11 912 errors........................................................................................................................ 137
4.6.12 940 errors........................................................................................................................ 138
4.6.13 950-958 errors ................................................................................................................ 138
4.6.14 959 error ......................................................................................................................... 140
4.6.15 96y error.......................................................................................................................... 142
4.6.16 97y error.......................................................................................................................... 144
4.6.17 98y error.......................................................................................................................... 145
4.6.18 99y error.......................................................................................................................... 146
4.7 Symptoms............................................................................................................................... 146
4.7.1 Base printer symptoms................................................................................................... 146
4.7.2 Dead machine service check.......................................................................................... 147
4.7.3 Controller board service check....................................................................................... 147
4.7.4 Control panel service check............................................................................................ 150
4.7.5 Control panel button service check ................................................................................ 151
4.7.6 USB print service check.................................................................................................. 151
4.7.7 Front door not closed service check............................................................................... 152
4.7.8 Network service check.................................................................................................... 153
4.8 ADF/Scanner hardware errors ............................................................................................... 157
4.8.1 8yy error messages........................................................................................................ 157

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4.8.2 Scanner disabled error service check ............................................................................ 158
4.8.3 Scanner carriage failure service check........................................................................... 160
4.8.4 ADF service check.......................................................................................................... 161
4.8.5 Scanner configuration error service check ..................................................................... 162
4.8.6 Scan/fax/copy symptoms................................................................................................ 162
4.8.7 Black or blank page copy service check......................................................................... 163
4.8.8 CCD service check ......................................................................................................... 164
4.8.9 Flatbed motor service check........................................................................................... 164
4.8.10 Flatbed home position service check ............................................................................. 164
4.8.11 ADF rattling noise service check .................................................................................... 165
4.8.12 Flatbed legal scan service check.................................................................................... 166
4.8.13 ADF streak service check............................................................................................... 166
4.8.14 ADF feed errors service check ....................................................................................... 167
4.8.15 ADF duplex service check (bizhub 4020 only) ............................................................... 168
4.8.16 Modem/fax board service check..................................................................................... 169
4.8.17 Blank spaces on incoming fax service check................................................................. 170
4.8.18 Stretched words on incoming fax service check............................................................. 170
4.8.19 Fax reception service check........................................................................................... 171
4.8.20 Fax transmission service check...................................................................................... 172
4.8.21 Fax error log codes......................................................................................................... 175
4.8.22 Escalating a fax issue to second-level support............................................................... 179
4.9 Input option hardware errors.................................................................................................. 181
4.9.1 321-344 errors ................................................................................................................ 181
5. Service menus .............................................................................................................................. 185
5.1 Diagnostics menu................................................................................................................... 185
5.1.1 Entering the Diagnostics menu....................................................................................... 187
5.1.2 Registration..................................................................................................................... 187
5.1.3 Scanner calibration......................................................................................................... 188
5.1.4 Print Tests....................................................................................................................... 188
5.1.5 Print Quality Pages......................................................................................................... 189
5.1.6 HARDWARE TESTS...................................................................................................... 189
5.1.7 DUPLEX TESTS............................................................................................................. 192
5.1.8 INPUT TRAY TESTS...................................................................................................... 194

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5.1.9 OUTPUT BIN TESTS ..................................................................................................... 194
5.1.10 BASE SENSOR TEST.................................................................................................... 195
5.1.11 DEVICE TESTS.............................................................................................................. 196
5.1.12 PRINTER SETUP........................................................................................................... 197
5.1.13 EP SETUP...................................................................................................................... 198
5.1.14 REPORTS....................................................................................................................... 200
5.1.15 EVENT LOG ................................................................................................................... 201
5.1.16 Scanner tests.................................................................................................................. 202
5.1.17 Exit Diags........................................................................................................................ 207
5.2 Configuration menu................................................................................................................ 208
5.2.1 Entering the Configuration menu.................................................................................... 209
5.2.2 Reset ADF Maintenance Kit Counter ............................................................................. 210
5.2.3 Reset separator roll and pick assembly counter............................................................. 210
5.2.4 Maintenance Counter Value........................................................................................... 210
5.2.5 Reset Maintenance Counter........................................................................................... 210
5.2.6 Print Quality Pages......................................................................................................... 210
5.2.7 Reports ........................................................................................................................... 210
5.2.8 Panel Menus................................................................................................................... 211
5.2.9 Tray Linking .................................................................................................................... 211
5.2.10 PPDS Emulation............................................................................................................. 211
5.2.11 Download Emuls............................................................................................................. 212
5.2.12 Safe Mode....................................................................................................................... 212
5.2.13 Factory Defaults.............................................................................................................. 212
5.2.14 Energy Conserve............................................................................................................ 212
5.2.15 Fax low power support.................................................................................................... 213
5.2.16 Min copy memory ........................................................................................................... 213
5.2.17 Num pad job assist ......................................................................................................... 213
5.2.18 Format fax storage.......................................................................................................... 213
5.2.19 ADF edge erase.............................................................................................................. 214
5.2.20 Flatbed edge erase......................................................................................................... 214
5.2.21 Scanner manual registration........................................................................................... 214
5.2.22 Disable scanner.............................................................................................................. 215
5.2.23 Paper Prompts................................................................................................................ 215