Konica 8020/8031 Copier Service Manual Set (2002)

The General Section explains how the tandem color engine works, and Field Service covers copier repair, calibration, and fault isolation. The setup guides show the installation order for the printer and its options, including when paper-reference adjustments must be completed before aligning the duplex unit.

Peripheral coverage centers on setup and alignment, with wiring and fault checks for selected options.

PDF Search, Bookmarks, and Wiring Detail

Finding text and reading diagrams: Text search works in parts of the file. Much of Field Service and the DB-432 guide use font encoding that interferes with search, and most wiring sheets have no searchable labels. Bookmarks cover the main sections and individual setup guides, with an occasional detailed link landing on the wrong page. Small pin numbers, connector IDs, and wire codes are easier to read at higher zoom.

The set comes as one printable, 628-page English PDF. The total includes the covers, section dividers, and 19 blank or blank-marked pages.

Copier Repair, Calibration, and Fault Isolation

This selection of service topics also includes examples from the broader coverage, such as optional original-size sensor installation and flash-memory firmware updates.

• Engine and paper path: Explains CCD scanner shading, four-color LED exposure, drum image formation, first and second transfer, fusing, paper transport, fan control, and image stabilization.

• Maintenance and replacement: Covers paper-feed roller and filter service, waste-toner handling, and replacement of imaging units, the transfer belt and roller, and the fusing unit.

• Scanner and electrical service: Details scanner-drive cable winding and removal of the CCD, LED print heads, toner hopper, control boards, motors, sensors, and power units.

• Service-mode calibration: Covers scanner focus, margins, magnification, color registration, gradation, toner-density sensing, second transfer, and fuser adjustments through Tech. Rep. Mode.

• Fault diagnosis: Uses I/O checks, misfeed timing, warning and malfunction codes, and test prints to trace paper jams, power faults, and image defects.

• Wiring and option setup: Includes connector layouts, copier and peripheral wiring, and setup checks for paper-feed, finishing, storage, and printer-controller options.

Konica recommends this documentation for Konica-trained service technicians. It assumes familiarity with high-voltage assemblies, moving mechanisms, hot fuser components, and service-mode settings.

Scanner and Color Engine Operation

The 8020 and 8031 share a tandem color engine, with different rated color copying speeds. The scanner section traces the signal from the exposure unit and CCD through original-size detection, gain and shading correction, and image processing. The printer section explains PIC board processing, LED gradation, FEET processing, GBTC compression, and color conversion.

The LED print head (LPH) material covers rank entry, chip adjustment, and correction for intensity, color shift, and skew. The linearity example shows how readings at 120 points produce correction data stored in EEPROM. Engine theory also explains polymerized toner, optical toner detection, oil-free fusing, new-unit detection, transfer-belt initialization, and automatic toner-density and transfer-voltage control.

Service Work and Post-Replacement Checks

Field Service covers scanner rails, mirrors, the lens and CCD, synchronizing rollers, and the waste-toner collection port. Board removal includes the image-processing and interface boards, image control and PIC boards, and the LED drive board. The electrical service material also covers the DC power supplies and high-voltage units.

The adjustment matrix links a unit or board replacement to the checks, resets, or settings that follow it. It helps a technician distinguish a hardware fault from a missed calibration after reassembly. The manual also covers touch-panel alignment, original-size detection, memory clearing, hard-disk checks, and Utility and Security Mode settings.

Tool references include scanner-cable holding jigs 65FA5111 and 65FA5112, LPH mounting jigs 65FA9905, imaging-unit pull-out jig 111T0013, and LED cleaning tools 111T5502 and 111T5503. Test charts are identified for image and alignment checks.

Konica flags two service precautions. Air-gun or vacuum cleaning can damage ATDC and related sensors through static discharge. Pulling the toner hopper while the bottle is turning can damage the drive or locking mechanism.

Fault Charts, Wiring, and Controller Setup

Tech. Rep. test prints separate scanner and image-processing faults from printer-engine faults. Single-color and four-color patterns then help narrow the cause to an imaging unit, transfer assembly, fuser, CCD path, interface cable, memory board, or PIC board. Misfeed charts trace the drawers, bypass, vertical transport, duplex path, second transfer, fuser, and exit. Power-supply checks distinguish a copier with no power from one where only the cooling fan runs.

The diagram appendix includes the four-sheet 8020/8031 overall wiring diagram, electrical parts and connector layouts, and the five-sheet circuit diagram shared with the Japan-market 9231 and 9331. Dedicated wiring sheets cover the DF-332, PF-232, DB-432, FS-135, FS-231, and AD-231.

The FS-231 guide covers staple and fold alignment. The IP-711 and Fiery guides cover controller installation, network configuration, and test printing. The Fiery guide also addresses print connection faults and Scan to FTP setup.

Sample Print Margin and Scanner Calibration Targets

For both models, the printer-side top-margin test pattern calls for 5.0 mm or 7.0 mm at the leading edge, each with a tolerance of ±1.0 mm. The target follows the erase setting in Administrator Mode, and the check applies after LED print head replacement.

For scanner magnification, the sample-copy targets are 200 ± 1.0 mm across the feed direction and 300 ± 1.5 mm along it. The first check applies after CCD or lens replacement. The second applies after work on the scanner assembly, motor, or drive cables.