Articles Directory

Remanufacturing the Konica Minolta 2400

• By Mike Josiah
• Oct 01, 2007

First released in January 2005, the Magicolor 2400 series of machines are based on a 20-ppm black, 5-ppm color print engine. The 2400 series has a base resolution of 600-by-600 dpi, enhanced resolution of 2400-by-600 dpi.

One interesting thing with these machines is, like the 2300 series, there is a humidity/temperature sensor that feeds information to the main PCB. This information is used to help determine what the DC bias voltages should be for optimum printing, and assists the fusing temperature control.

Unlike the previous 2300 series, these machines use chips on the toner cartridges, and they must be replaced each cycle. There are also different chips used for different regions around the world. Make sure you have the correct chip for your region.

The machines based on the 2400 series engine are:

• Magicolor 2400W
• Magicolor 2430DL
• Magicolor 2450
• Magicolor 2480MF
• Magicolor 2490MF
• Magicolor 2500WF
• Magicolor 2530DL
• Magicolor 2550DN
• Magicolor 2550EN

Although, at first glance, the 2300 cartridges look the same as the 2400 series, they are very different. See Figures 1 and 2. Note that the gears are on opposite sides, the handles are different, etc.

There are high-yield cartridges as well as low-yield cartridges available. As stated above, the cartridges have different part numbers (chips), for different regions around the world. In addition to the toner cartridges, there is also a separate drum unit as well as a waste box.

The cartridges used by these machines by region are as follows:

(*Pricing does not include shipping.)

These machines are based on a carousel type color engine. It is virtually identical in design to the 2300 series so there is no need to go into the theory again here.

One interesting note is that sometimes when the printer stops, the carousel does not stop in a position where a cartridge can be removed. This happened multiple times to us, on multiple machines. Even when you tell the printer to rotate it sometimes does not stop in the correct location. Konica Minolta apparently knows this as they have included a release switch that can be accessed from the right side of the printer with a small screwdriver or pen. Depressing this switch allows the carousel to freely rotate and you can then remove the cartridge(s). See Figure 3.

Taking test prints, as well as minor printer troubleshooting, will be covered at the end of this article.

Remanufacturing instructions

1) Remove the fill plug, and dump out any remaining toner. See Figure 4.

2) On the gear side of the cartridge, remove the three silver screws from the end cap. See Figure 5.

3) Remove the end cap. See Figure 6.

4) Remove the larger drive gear and the two smaller gears next to it. Leave the mixing blade gear in place. See Figure 7.

5) Remove the doctor blade contact screw. See Figure 8.

6) Remove the contact/bushing assembly. See Figure 9.

7) Remove the white bushing from the non-gear side by prying up the center tab and rotating the bushing counterclockwise until it stops. Pry the bushing off the developer roller shaft. See Figures 10 and 11.

8) Remove the doctor blade cover by prying up the three tabs as indicated. Remove the cover. See Figure 12.

9) Remove the developer roller and gears. See Figure 13.

10) Remove the two screws from the doctor blade. Remove the doctor blade. See Figure 14.

11) Remove the three screws on the sealing blade assembly. See Figure 15.

12) Pry up the sealing blade assembly and lift off. The entire foam seal assembly will come off with it. Be careful not to tear the foam seals. See Figure 16.

13) Clean out any remaining toner from the hopper and the feed roller. See Figure 17.

14) Remove the small screw from the feed roller contact plate. Remove the plate. See Figure 18.

15) Check to ensure that the contact to the feed roller is clean, and that the two gears are clean and greased. If not, clean them and re-grease the gears with white lithium grease. See Figure 19.

16) Re-install the feed roller contact plate and screw. See Figure 20.

17) Install the cleaned sealing blade assembly, seals, contact and three screws. Make sure the foam aligns with the plastic pins. See Figure 21.

18) Install the doctor blade and two screws. See Figure 22.

19) Install the developer roller assembly. See Figure 23.

20) On the non-gear side, install the large white bushing tab up, and rotate clockwise to lock in place. See Figures 24 and 25.

21) Install the three gears from smallest to largest. See Figure 26.

22) Install the contact/bushing assembly and screw. See Figure 27.

23) Install the black end cap on the gear side. Install the three silver screws. See Figure 28.

24) Install the doctor blade cover. Rotate so that the tabs are aligned and snap in place. This may take a bit of force to fit properly. See Figure 29.

25) Fill with the appropriate 2400 color toner. Replace the fill plug. See Figure 30.

26) Replace the chip by removing the small Phillips screw. See Figure 31.

27) Install the developer roller cover. See Figure 32.

Taking test prints

With the printer ready, press the "MENU SELECT” button once.

Press the left or right arrows until "SPECIAL PAGES” appears on the display.

Press the "MENU SELECT” button.

Press the left or right arrows until "TEST PAGES, PRINT,” "CONFIG PAGE” or "PRINT MENU MAP” appears on the display (your choice).

Press the "MENU SELECT” button.

Common printer error messages

Most error codes are self-explanatory, but a few are numeric. We have included some of the more common ones here.

• Fatal Error 08H Main motor not rotating
• Fatal Error 0BH Fan motor not rotating
• Fatal Error 0CH Power supply fan not rotating
• Fatal Error 10H Scanner motor error
• Fatal Error 12H Laser failure
• Fatal Error 16H Transfer belt not rotating
• Fatal Error 17H Toner cartridge rack not rotating
• Fatal Error 18H Fuser assembly warm up error
• Fatal Error 19H Fuser assembly low heat error
• Fatal Error 1AH Fuser assembly high heat error
• Fatal Error 1BH Fuser assembly thermistor error

Mike Josiah is vice president of technical services at Summit Technologies, a division of Uninet Imaging Inc., global distributor of toner, OPC drums, wiper blades and other supplies. Josiah has been with the company since 1987. He and his technical support team regularly contribute articles and teach seminars at association meetings and trade shows. Contact Mike Josiah at 631-218-8376 or mjosiah@uninetimaging.com.