Error Code C0204 is a Tray 2 Feeder Up/Down Abnormality on Konica Minolta bizhub machines. It occurs when the machine commands Tray 2's lift-up motor to raise the paper stack to the feed position, but the upper limit sensor does not confirm that the tray has reached the correct height within the allowed time window

The machine indicates one of three scenarios: the tray is not physically reaching the upper limit, the upper limit sensor cannot detect the tray, or the lift motor is not running at all. Each scenario requires a different diagnostic approach. The service mode sensor and motor checks are critical for quick isolation.

All Affected Models and Exact Component References

C0204 is documented across nearly every major bizhub generation with Tray 2 installed. The motor designation, sensor name, and connector path differ significantly between model families. Using the correct references for your model saves diagnostic time and prevents checking the wrong components.

Main Tray 2 Models (No PC Cabinet)

C0204 with Option Cabinets (PC-110 / PC-210 / PF-P20 / PF-P21)

When PC-110, PC-210, PF-P20, or PF-P21 option cabinets are installed, the motor and sensor references may change to differentiate the Tray 2 inside the main unit from Tray 2 inside the option cabinet. Verify with the service manual and the parts list for the specific option installed.

• Default motor for Tray 2 (main unit): M13
• Default upper limit sensor for Tray 2 (main unit): PS22
• Option cabinet PF-P20/PF-P21 vertical motor references: follow the specific service manual for that cabinet.
• C0204 with PC-110 or PC-210 installed: refers to the Tray 2 inside the main machine, unless explicitly noted.

What Does Error Code C0204 Mean?

Every paper tray in the bizhub has a lift mechanism that raises the paper stack up to the feed roller level when the tray is closed.

The lift cycle for Tray 2 works as follows:

1. The tray is inserted and the machine detects it is closed.
2. The control board (PRCB, MFPB, or PFTDB) commands the lift-up motor (M13 or M8) to run.
3. The motor drives a gear train connected to the tray bottom plate, raising it upward.
4. When the paper stack reaches the correct height, the top sheet contacts and blocks the upper limit sensor (PS22, PS25, PS14, PS2/2).
5. The sensor signals the control board that the tray is at the correct position, and the motor stops.

C0204 fires when step 4 never happens — the upper limit sensor is not blocked within the allowed time after the lift motor was commanded to start.

There are three distinct failure scenarios:

• Scenario A — Tray reaches position but sensor does not detect it: The paper tray physically reaches the upper limit, but the sensor flag is misaligned, the sensor itself has failed, or its connector is faulty.
• Scenario B — Tray does not reach position: The lift motor is running but the tray cannot reach the upper limit because of a mechanical obstruction, worn/broken lift gear, or insufficient motor torque.
• Scenario C — Lift motor does not run at all: The motor receives no drive signal due to a connector fault, blown ICP/fuse, or failed motor.

Step 1 — Check for Paper Fragments Inside the Machine

This is the officially documented first step for C0204 on most bizhub models — and it is frequently the actual cause, especially after a recent paper jam.

1. Pull Tray 2 completely out of the machine.
2. Use a flashlight to inspect the tray cavity — check the bottom and sides for any torn paper, crumpled sheet, or paper fragment that has fallen into the tray mechanism area.
3. Also check the area beneath and around the tray for any debris.
4. Remove any paper found — even a small piece of paper wedged under the tray lift cam can stop the bottom plate from reaching the upper limit sensor.
5. Reinsert the tray and power cycle the machine — if C0204 clears, the cause was residual paper. Run a test print from Tray 2 to confirm stable operation.

Step 2 — Check Tray 2 Is Fully and Correctly Inserted

1. Pull Tray 2 out completely and reinsert it with a firm, positive push until you feel and hear it click into its fully closed position.
2. Check that the paper is loaded correctly and within the tray's maximum capacity line. Overfilled trays can prevent the tray from seating fully and can also prevent the paper stack from fitting within the lift range.
3. Power cycle and test.

Step 3 — Inspect and Reseat the Motor and Sensor Connectors

A loose connector at M13 (or M8) or the upper limit sensor is a very common cause of C0204, especially after a PM visit or any service that involved the paper feed area. Use the exact connector references from your model in the table above.

For bizhub C224 / C284 / C364 / 4e family (PRCB models):

1. Power OFF and unplug the machine.
2. Reseat the connector at: M13 → PRCB CN20 (lift motor connector).
3. Reseat the connector at: PS22 → relay CN40 → PRCB CN19 (reseat both the relay connector and the PRCB end).
4. Inspect all pins for damage, oxidation, or toner contamination.

For bizhub 227 / 287 / 367 / C227 / C287 / C367 (MFPB models — F5E on MFPB):

1. Power OFF and unplug the machine.
2. Reseat: M13 → MFPB CN7E (or CN8E depending on the variant).
3. Reseat: PS25 → relay CN55 → MFPB CN5E (or relay CN49 → MFPB CN11E).

For bizhub C258 / C308 / C368 / C458 / C558 / C658 (MFPB models):

1. Power OFF and unplug the machine.
2. Reseat: M13 → MFPB CN25E.
3. Reseat: PS22 → relay CN40 → MFPB CN23E.

For bizhub 654 / 754 / C654 / C754 (PFTDB models):

1. Power OFF and unplug the machine.
2. Reseat: M8 connector → PFTDB CN26.
3. Reseat: PS14 connector → relay CN15B → PFTDB CN14.

For bizhub 223 / 283 / 363 / 423:

1. Reseat: M12 → PRCB CN14.
2. Reseat: PS12 → relay CN2 → PRCB CN15.

After reseating all connectors, power on and test with a Tray 2 print job. If C0204 clears, monitor for recurrence — if it returns, the connector housing or pin contact is degraded and should be replaced.

Step 4 — Perform the Upper Limit Sensor Check in Service Mode

The service mode sensor check tells you within seconds whether Scenario A (sensor not detecting) or Scenario B/C (tray not reaching position) is the actual cause. This is the most important diagnostic step before replacing any component.

1. Enter Service Mode (refer to your model's service manual for access).
2. Navigate to the sensor I/O check or sensor monitor section.
3. Monitor the upper limit sensor (PS22, PS25, PS14, or PS2/2 per your model) at the signal pin shown in the table.
4. With Tray 2 removed, confirm the sensor reads OFF (unblocked).
5. Manually push the tray bottom plate upward by hand until it reaches the upper limit position — the sensor flag should enter the sensor beam and the signal should switch to ON.
6. Interpret the result:
   • Sensor switches ON when flag reaches it: The sensor is working correctly. Proceed to Step 5 to check the lift mechanism.
   • Sensor does NOT switch ON even when the flag physically enters the beam: The sensor has failed or its connector is faulty. Replace the sensor (Step 7).
   • Sensor reads ON permanently with no flag present: The sensor flag is stuck in the beam, or the sensor has failed in the triggered state. Inspect the flag physically and replace the sensor if the flag is clear.

Step 5 — Perform the Lift Motor Operation Check in Service Mode

After confirming the sensor status, run the motor operation check to verify M13 (or M8) receives and responds to a drive command.

1. In Service Mode, navigate to the motor operation / load check section.
2. Command M13 (or M8) to run using the operation check function:
   • C224/C284/C364/4e family: M13 operation check via PRCB CN20-5 (REM) (Location: 2-C)·
   • 227/287/367 family: M13 operation check via MFPB CN7E-13 to 14 (Location: 23-C)·
   • C258/C308/C368 and C458/C558/C658 family: M13 operation check via MFPB CN25E-5 (REM) (Location: 22-C)·
   • C654/C754 family: M8 operation check via PFTDB CN26-10 to 11 (Location: 4-X)·
3. Observe the motor: it should run immediately and the tray bottom plate should begin to rise.
4. Interpret:
   • Motor runs, tray rises but stops short of sensor: Mechanical fault in lift gear/cam assembly — proceed to Step 6.
   • Motor runs, tray rises and reaches sensor correctly: C0204 was caused by a connector issue or transient. Run a full print test.
   • Motor does not run despite correct operation check command: No drive signal reaching motor. Check ICP/fuse (Step 8). If ICP is intact, replace motor (Step 7).

Step 6 — Inspect the Tray 2 Lift Mechanism

If the motor runs but the tray does not rise fully to the sensor position, there is a mechanical failure in the lift gear train or cam assembly.

1. Power OFF and unplug the machine.
2. Remove Tray 2 completely.
3. Access the tray lift mechanism — typically visible by looking into the tray cavity from the front of the machine or by removing the right-side cover depending on the model.
4. Inspect the following components:
   • Lift cam(s) — check for cracks, worn contact surface, or a cam that has slipped off its shaft.
   • Lift gear train — trace the gear path from M13 to the lift cam. Look for stripped teeth, a cracked gear hub, or a gear that has split off its shaft and is spinning freely.
   • Tray bottom plate linkage — check for a broken arm, a bent pivot, or a link that has come disconnected.
   • Tray bottom plate itself — look for a bent plate that is catching on the tray frame before reaching the sensor height.
5. Manually rotate the lift cam by hand while watching the bottom plate — the plate should rise smoothly and evenly.
6. Replace any damaged lift cam, gear, or linkage component.

Step 7 — Replace the Lift Motor or Upper Limit Sensor

Replace M13 / M8 if the motor operation check confirms the drive signal is present at the motor connector but the motor does not run:

• Replacement steps: power OFF and unplug, access the motor (typically behind the right-side cover near the paper feed assembly), disconnect the harness, remove mounting screws, extract the motor, install the replacement motor, ensure the coupling engages correctly, and reconnect.
• Part numbers: For many models, M13 = 9J06M10300；· for C654/C754, M8 = A3CKM10400·.

Replace PS22 / PS25 / PS14 / PS2/2 if the sensor I/O check confirms the sensor does not switch state when its flag is physically actuated:

1. Locate the upper limit sensor in the tray cavity area — a small photo-interrupter sensor mounted on a bracket above the tray's upper travel limit.
2. Before replacing, confirm the sensor flag is not bent, broken, or missing — a missing flag means the sensor can never be triggered regardless of the tray position.
3. Replace or straighten the flag if damaged before installing a new sensor.
4. Disconnect the sensor harness, remove the mounting screw(s), and fit the replacement sensor.
5. Power on and confirm the sensor switches correctly in the service mode I/O check.

Step 8 — Check ICP4 (PRCB) or F5E/F13E (MFPB) Continuity

On models where the motor does not respond to the operation check and no drive signal is present at the motor connector, check the inline circuit protector before replacing the control board.

For bizhub C224 / C284 / C364 / 4e family (PRCB models):

1. Access the PRCB and locate ICP4·. Test continuity with a multimeter — no continuity confirms ICP4 has blown.
2. A blown ICP4 requires PRCB board-level repair or full PRCB replacement.
3. Before replacing the PRCB, confirm M13 is not seized — a seized motor caused the overcurrent that blew ICP4.

For bizhub 227 / 287 / 367 / C227 / C287 / C367 (MFPB models):

1. Access the MFPB and locate fuse F5E· or F13E· Test continuity. No continuity confirms the fuse has blown.
2. A blown fuse requires MFPB board-level repair or replacement. Check that no motor is seized before replacing the board.

For bizhub 654 / 754 / C654 / C754 (PFTDB models):

1. Access the PFTDB and locate ICP10·
2. Test continuity; if blown, replace the PFTDB.

Step 9 — Replace the Control Board (Last Resort)

If a confirmed-good motor, confirmed-good sensor, intact ICP/fuse, and clean connectors still produce C0204, the fault is in the control board's motor drive output or sensor input circuit.

• Replace PRCB — bizhub C224/C284/C364/4e family, C454/C554, 223/283/363/423 (PRCB part number: A5C1H00102 for C364e)
• Replace MFPB — bizhub 227/287/367, C227/C287/C367, C258/C308/C368, C458/C558/C658 (MFPB part number: A7PUH02123 for C368)
• Replace PFTDB then PRCB — bizhub C654/C754, C452/C552/C652 (PFTDB part number: A2X0H00202 for C754, PRCB part number: A2X0H00102 for C754)

Quick Reference — Troubleshooting by Symptom

The table below summarizes the most common C0204 symptoms and their likely root causes, following the same diagnostic logic as the C0202 guide.

Understanding the C020x Tray Lift Error Family

C0204 is one of a set of lift-up errors that follow the same detection logic across all paper trays. If you are seeing multiple codes from this family together, a shared power rail or communication failure is almost always the cause rather than multiple simultaneous individual tray failures:

• C0202 — Tray 1 lift-up failure (upper limit sensor not blocked)
• C0204 — Tray 2 lift-up failure (upper limit sensor not blocked)
• C0206 — Tray 3 lift-up failure (When PC-110 or PC-210 is installed)
• C0208 — Tray 4 lift-up failure (When PC-210 is installed)
• C0210 — LCT lift-up failure (When PC-410/PC-415 installed)
• C0211 — Bypass tray lift-up failure
• C0212 — LCT tray descent failure

C0202 and C0204 appearing simultaneously points to a shared board fault — both Tray 1 and Tray 2 lift motors are controlled through the same PRCB or MFPB, and a blown ICP or failed board power rail affects both trays at once. Check ICP (PRCB) or F5E/F13E (MFPB) continuity before any board replacement in this scenario.

Preventing C0204 From Recurring

• Always clear paper jams completely before closing trays — paper fragments in the tray lift mechanism are the most common cause of C0204. Spend an extra 60 seconds with a flashlight after every tray 2 jam to confirm the lift area is clear.
• Do not overfill Tray 2 — paper loaded above the maximum fill line prevents the tray from closing fully and puts excessive load on the lift motor during every lift cycle, accelerating wear on the lift cam and gear train.
• Reseat the M13 and PS22/PS25 connectors at every PM visit — these connectors accumulate paper dust and toner. A 60-second reseat and inspection during routine maintenance prevents the most common connector-related C0204 calls.
• Inspect the lift cam and gear train during PM on high-volume machines — the lift mechanism cycles on every tray open/close. On high-volume machines, inspect the lift cam and coupling gears for wear during major PM visits and replace proactively before they fail completely.
• Check the sensor flag condition during PM — the small plastic flag that triggers the upper limit sensor can become bent or broken over time. A quick visual check catches this before it causes a service call.

Professional Technician Summary

Error Code C0204 on Konica Minolta bizhub machines is a Tray 2 lift failure, and the fastest path to resolution starts with the service mode sensor check — not with replacing components.

In office environments, the most common cause is a paper fragment in the tray cavity from an incompletely cleared jam at Tray 2. Remove the tray, check with a flashlight, and C0204 clears in two minutes.

When the machine has a genuine hardware fault, the sensor I/O check immediately tells you which scenario applies: if the sensor switches correctly when the flag enters manually but C0204 still fires, the motor is not lifting the tray high enough — check the lift mechanism. If the sensor never switches even with the flag physically inside the beam, replace the sensor.

Always check ICP4 (PRCB) or F5E/F13E (MFPB) or ICP10 (PFTDB) before replacing the control board when the motor does not respond — a blown ICP is significantly cheaper to address than a full board replacement and is the correct cause when a seized motor previously created an overcurrent condition.

For PFTDB-based models like the C654/C754, the troubleshooting path is different: after confirming the tray is clear, check connectors and M8- PFTDB CN26, then proceed to PFTDB ICP10 and PFTDB replacement before considering PRCB replacement·

This guide reflects service manual procedures for the bizhub models listed. Always refer to the official Konica Minolta service literature for your exact model. Part numbers are provided as references; always confirm the latest revision before ordering any components.