Service History — Fort Mill, SC — Page 2

Problem: A Xerox VersaLink C405 in Fort Mill repeatedly prompted for black toner replacement and a restart, persisting after two separate toner cartridges were installed.

Solution: Firmware reset restored black toner recognition; calibration and print-quality adjustments were performed to confirm full functionality.

Problem: Zebra ZQ520 portable thermal printer reported with worn printhead and platen roller requiring replacement.

Solution: Technician replaced the printhead and platen roller on a Zebra ZQ520 (model ZQ52-AUE0000-00) portable barcode printer. Part of a multi-unit service involving six printers requiring the same components.

Problem: Customer in Cornelius, NC required two HP LaserJet M507n laser printers for their commercial operation.

Solution: Two HP LaserJet M507n units were sourced and placed on order; equipment was on backorder with an estimated arrival of May 11, 2022.

Problem: A Zebra ZM400 thermal printer in Pineville, NC was generating multiple errors traced to a faulty cutter assembly.

Solution: Technician replaced the cutter assembly, cleaned the unit, performed calibration, and tested to confirm normal operation.

Problem: HP LaserJet MFP E52645dn required unboxing, assembly, and full configuration as a new installation at a Charlotte, NC business.

Solution: Technician unboxed and assembled the unit, configured network, fax, and scan-to-email settings, verified all paper trays fed correctly, and confirmed ADF and flatbed copies were clean. Customer's IT department retained responsibility for print driver deployment.

Problem: Zebra 105SL Plus thermal printer in Mount Holly, NC required parts installation; components had been shipped to the customer site in advance of a scheduled service visit.

Solution: Parts were shipped to the customer site for the Zebra 105SL Plus. Upon follow-up, the customer reported the unit was operating normally and requested the service visit be postponed. The call was subsequently closed with no installation performed.

Problem: Brother MFC-8950DW displayed a persistent low drum warning and repeated 'Over Heating' pauses during large print jobs, halting output multiple times per run.

Solution: Technician found the drum unit at 6% life with visible wear and reset the counter to prevent shutdown pending replacement. Fuser pressure roller showed heavy wrinkling. A repair quote was issued covering the fuser, Tray 1 pickup roller assembly, Tray 1 separation pad, drum unit, ADF pickup roller as

Problem: HP LaserJet 500 MFP M525f repeatedly jammed with persistent error 13.B2.D2. Prior roller and tray replacements had not resolved the fault.

Solution: Inspection revealed the Tray 2 pickup assembly's left and right tray stabilizers were broken. Replaced the Tray 2 paper pickup assembly (RM1-8505) and Tray 2 separation pad (RM1-6303). Machine was repositioned for access, cleaned thoroughly, and tested — error and jamming cleared.

Problem: An HP LaserJet M527 in Belmont, NC was producing streaked lines across all scanned documents.

Solution: Technician cleaned the ADF scanning glass, eliminating the scan lines, then identified a grinding noise from ADF gearing. The full ADF assembly (B5L47-67906) was replaced and the machine was cleaned and tested.

Problem: HP LaserJet M3035 (CC477A) reporting a persistent ADF jam error at 65,376 pages. No physical jam could be located within the ADF assembly.

Solution: Inspected the ADF thoroughly; no obstruction found. The jam-present sensor was inaccessible for bench-level verification, indicating likely sensor failure or internal ADF fault. Customer was advised a replacement ADF unit would be required. ADF was left disconnected to clear the fault state, and end

Problem: HP Color LaserJet MFP M476dw was not visible on the network. The device had been configured for wireless but printer menu settings were locked by IT administration.

Solution: Technician connected the M476dw via Ethernet; the printer acquired an IP address, confirming the hardware was functioning correctly. IT reconfigured network settings, restoring full network printing capability.

Problem: Zebra 105SL thermal label printer due for scheduled quarterly preventive maintenance (3 of 4 in annual PM cycle).

Solution: Performed quarterly PM on Zebra 105SL: cleaned adhesive buildup from printhead and platen roller, inspected drive belts and gears, and verified print quality.

Problem: Xerox Phaser 3600 laser printer in Kannapolis experienced continuous paper feeding from Tray 2, resulting in repeated jams.

Solution: Technician diagnosed a stuck Tray 2 solenoid caused by a foreign sticky substance. Solenoid was freed, residue removed, and unit tested with no further feed or jam issues.

Problem: Zebra 170Xi4 300 DPI thermal printer in Matthews, NC reported degraded print quality — output alternated between overly dark and light or blotchy results.

Solution: Technician cleaned the printhead; print quality remained unacceptable. Adjusted pressure, temperature, and print speed without resolution. Replaced the printhead (part P1004237) and fine-tuned pressure and temperature settings to restore consistent, acceptable print quality.

Problem: A Zebra ZT410 thermal printer in Fort Mill was not properly feeding labels through the media path.

Solution: Technician confirmed the feed issue on-site, found the drive belt had severe wear, and replaced it with a customer-supplied belt. End user was trained on printhead pressure adjustment to eliminate void lines on printed labels.

Problem: A Zebra 105SL thermal printer in Mount Holly, NC required a PM13-level service, with the printhead, tension spring, ribbon roller, main board, and media sensor all flagged for replacement.

Solution: Technician replaced the printhead (300 DPI), toggle assembly, ribbon roller kit, media sensor, and main board on the Zebra 105SL 10500-3001-2000. Unit was tested and confirmed operational following component replacement.

Problem: HP LaserJet 500 MFP M525 producing a loud, repetitive knocking noise during operation.

Solution: Diagnosed the noise to a defective toner cartridge at approximately 40% life remaining. Replaced the cartridge, cleaned the printer, and confirmed the thumping noise was fully eliminated upon test printing.

Problem: A Sato M10e thermal printer was triggering a persistent open-head error. The unit is operated in an inverted orientation, and labels were found jammed in the media path.

Solution: The technician cleared stuck labels from the media path, then bent the metal arm on the open-head switch assembly so the switch activates fully when the print head is closed. With a customer-supplied ribbon installed, all adjustments were verified and the printer was tested before return to service

Problem: Zebra 105SL thermal printer in Monroe, NC reached end of serviceable life and was designated for disposal following a PM10 assessment.

Solution: Technician decommissioned the Zebra 105SL, harvesting all recoverable components before the unit was disposed of.

Problem: HP LaserJet M608 in Charlotte reported severe, persistent jamming originating from Tray 3, even after a recent maintenance kit installation that included new rollers and a fuser.

Solution: Replaced Tray 2 and Tray 3 feed rollers. Located and removed a hidden torn-paper fragment lodged in the Tray 2 feed path. Cleaned the machine thoroughly and confirmed jam-free operation through test prints.

Problem: Brother MFC-9340CDW in Indian Trail producing vertical lines down the page on printed and copied output.

Solution: Diagnosed lines as caused by a defective remanufactured black toner cartridge. Swapped between the reman and original cartridges multiple times to confirm. Adjusted copy scan darkness settings to optimize output. Original Brother toner showed no lines but was nearly depleted; replacement toner was r

Problem: HP LaserJet P4015 experiencing paper jams at the fuser. Unit required a maintenance kit; multiple cassette tray guides were also broken across the fleet.

Solution: Installed maintenance kit and reset the page count. Repaired broken cassette tray guides on seven of eight trays using self-tapping steel screws, securing each guide to letter-size position. Tested printer after servicing.

Problem: HP LaserJet 9050 presented with toner specks, smears, streaks, and repeated paper jams under normal office print loads.

Solution: Technician replaced the maintenance kit on the HP LaserJet 9050 and verified clean, jam-free output across test prints.

Problem: Zebra ZT510 and 105SL Plus thermal printers required printhead replacement.

Solution: Replacement printheads were quoted, approved, and ordered for both the Zebra ZT510 and 105SL Plus. Parts shipped directly to the customer's Mount Holly, NC location.

Problem: HP Color LaserJet 700 M775 reported making loud noises and producing lines in printed output.

Solution: Diagnosed noise as low black and cyan cartridges; replaced both along with a low magenta toner. Identified transfer belt as the cause of print lines. Installed CE516A transfer kit with included rollers and reset the page count. Tested unit and confirmed noise and line defects resolved.

Problem: HP Color LaserJet CP5225 in Rock Hill, SC was producing vertical streaks down printed pages and experiencing repeated paper jams.

Solution: Inspection revealed a failing transfer belt cleaner blade, toner buildup in the collection unit, and worn tray feed rollers — accelerated by exclusive use of letter-size media in a printer optimized for 11×17 and duplex output. Quoted replacement of the CE980A toner collection unit and CE516A transf

Problem: A Zebra ZT410 thermal printer in Fort Mill was producing misaligned output, with print content shifting from the center of labels and bleeding across two labels.

Solution: Inspection revealed multiple rubber bands wrapped around the label gap sensor assembly — left by a previous user to hold the label guide in place. The rubber bands were removed, the label guide was properly repositioned, and test labels confirmed consistent, centered output with no shifting.

Problem: HP DesignJet 500ps 42" (C7770C) reported error 21:10, indicating a service station fault.

Solution: Technician oiled the carriage rod and freed the stalled service station by manually cycling the drive gear. Plotter returned to operation; service station flagged for potential replacement if the error recurs.

Problem: HP LaserJet 8000 in Rock Hill, SC not pulling paper from Tray 2.

Solution: Diagnosed a broken Tray 2 lifter in the paper input unit; replacement parts are no longer available due to the printer's age. Tray 2 was configured as an odd paper size and type and marked out of service. Tray 3 was set as the default paper source and its feed rollers were cleaned.

Problem: Zebra 105SL thermal printer reported a persistent Ribbon Out failure. Ribbon sensor or main board suspected defective; platen roller also required replacement.

Solution: Technician adjusted ribbon sensor settings, restoring print operation. Replaced platen roller, printhead, and media guide using parts units. Installed a replacement network card. Printer was tested and returned to service.

Problem: HP Color LaserJet M570DN MFP reported for service in Charlotte, NC with approximately 44,498 pages on the counter.

Solution: Technician performed cleaning and functional testing on the HP Color LaserJet M570DN MFP. Print quality verified close to manufacturer specification upon completion.

Problem: HP Color LaserJet MFP M477fnw required replacement; existing unit was being decommissioned and a recertified replacement needed to be deployed at the Gastonia, NC location.

Solution: Technician delivered and installed the HP CLJ M477fnw MFP (page count 130). Replacement unit was configured with the same static IP address as the decommissioned printer to minimize network reconfiguration. Old unit was left on-site pending customer instructions. Basic functionality confirmed before

Problem: Zebra ZT230 (203 dpi, ZPL) arrived without a network option card installed, leaving the unit unable to connect to the wireless network.

Solution: Technician installed a ZebraNet Internal Wireless 802.11n radio (part P1058930-097A) into the ZT230. Customer retained responsibility for configuring network settings post-installation.

Problem: Brother MFC-L8900CDW not printing to certain queues, duplex function non-functional, and extra blank sheets feeding between print jobs.

Solution: Diagnosed root cause as corrupted or misconfigured print drivers rather than a hardware fault. Reinstalled and corrected drivers on two units, restoring duplex printing and eliminating the extra-sheet issue.

Problem: A Zebra 105SL industrial thermal printer in Gastonia, NC was due for preventive maintenance and required replacement of the printhead, toggle assembly, ribbon roller, and ribbon strip plate.

Solution: Technician replaced the 300 DPI printhead (G32433M), toggle assembly (35099M), ribbon roller kit (P1006101), and ribbon strip plate (48017). All components were installed and tested to confirm proper operation.

Problem: A Zebra ZM400 thermal printer in Concord, NC was due for a PM5-level preventive maintenance service.

Solution: Performed PM5 service on the Zebra ZM400: cleared accumulated dust throughout the unit, cleaned the platen roller, inspected the printhead condition, and tested print output — unit passed with print quality within acceptable margins.

Problem: HP DesignJet T2500PS MFP would not complete boot sequence, throwing multiple error codes and producing a loud humming noise from the rear of the unit.

Solution: Diagnostics confirmed error 06:3:10 (hard drive failure); the Rev A hard drive was replaced, restoring boot but triggering a 79:04 firmware error. Firmware was downloaded and flashed over the network. The humming traced to two cooling fans with failing bearings; both were replaced (CR357-67048). Uni

Problem: Zebra ZT410 thermal printer in Kannapolis would not print due to a mismatch between printer settings and software/driver configuration.

Solution: Aligned printer settings with software requirements and adjusted the print driver to match operational needs. Configured the onboard cutter to automatically cut after each label using the installed media stock. Demonstrated cutter enable/disable procedure to the end user.

Problem: HP LaserJet 4250 on a production floor reported a feed-related issue requiring roller service at 210,110 page count.

Solution: Replaced two RM1-0037 pick/feed rollers on the HP LaserJet 4250. Installed Q5942X toner cartridge and tested the unit under production-floor conditions; device fed and printed correctly.

Problem: Sato RWG500 label rewinder reported with a loose screw, later confirmed to be a screw broken off at the rewinder shaft.

Solution: Inspection revealed a fastener broken at the rewinder shaft; the torque limiter and timing belt pulley could not be removed to replace the shaft. A replacement Sato RWG500 label rewinder (part #11S000201) was sourced and installed. Functionality was verified after installation.

Problem: Zebra GX430t thermal printer in Kannapolis, NC was due for scheduled preventive maintenance and presented with a broken cutter mechanism and missing hardware screws.

Solution: Technician completed full PM on the Zebra GX430t: replaced missing screws, repaired the cutter, removed adhesive residue, lubricated moving components, then calibrated and reconfigured the printer before final test.

Problem: HP LaserJet M601 producing poor print quality with smearing and smudges across output pages.

Solution: Diagnosed smudging to a failing fuser. Installed a spare used fuser as an interim measure to restore operation, then replaced with a new CF064A maintenance kit and reset the page count. Verified print quality after final installation.

Problem: Sato M8400RVe thermal transfer printer in Rock Hill, SC was producing completely blank labels, with no ink transfer visible on the ribbon.

Solution: Technician verified correct ribbon and label media were installed and confirmed dip switch settings matched thermal transfer mode. Print head connections were reseated at both ends. Ribbon showed no signs of ink transfer after testing, indicating a deeper mechanical or print head fault. Customer ele

Problem: HP LaserJet MFP M225dw in Charlotte was stuck in a continuous initializing loop. A replacement unit had been installed, as the previous printer exhibited the same symptom.

Solution: Technician found the printer powered through an overloaded APC 600 VA UPS with a 10-outlet power strip daisy-chained to its existing 6 outlets. Relocating power to a wall outlet and draining residual power produced no change. Booting without the toner cartridge and performing a permanent memory init

Problem: Zebra 110Xi4 thermal printer reported with a paper-out error and all indicator lights illuminated simultaneously.

Solution: Technician retrieved the unit and bench-tested it at the shop. The printer produced clean output with no errors, fault lights, or abnormal behavior. No repairs were required; the device was likely confused with a different malfunctioning unit.

Problem: Three Zebra ZM400 industrial thermal printers at an Indian Trail, NC facility were due for scheduled quarterly preventive maintenance.

Solution: Performed quarterly PM on three of five Zebra ZM400 units: cleaned internal components and print mechanisms, tested print quality and mechanical operation; all units passed inspection.

Problem: HP LaserJet MFP M630 reported labels stuck on the Tray 3 pickup rollers, causing feed failures in the paper path.

Solution: Disassembled Tray 3 assemblies to clear labels from the feed path. A label lodged in an inaccessible section of the assembly could not be removed without risking damage, requiring full replacement. Installed paper pickup assembly (RM2-0341-000CN) for Tray 3 and tested — unit returned to normal opera

Problem: Customer purchased a new 36" HP DesignJet T830 wide-format plotter requiring professional unboxing, assembly, and installation at their Matthews, NC location.

Solution: Technician unpacked and inspected the T830, assembled the plotter and stand, and relocated the unit to its final position. Initial testing with letter-size media confirmed basic print functionality; roll paper was not yet on-site. The original unit arrived with missing mounting hardware, a broken in

Problem: HP LaserJet P3015 reported recurring paper jams affecting normal print operations.

Solution: Technician cleaned the feed rollers and tray assembly, clearing heavy dust accumulation. Test prints confirmed jam-free operation at 256,033 page count.

Problem: A Zebra ZT410 thermal printer in Cornelius, NC was experiencing intermittent label feed failures, initially reported as a possible sensor issue.

Solution: On-site inspection revealed a worn spot on the drive belt rather than a sensor fault. The worn drive belt (part #79866M, 203 dpi ZT410 series) was replaced, and full label feeding operation was verified with no further issues found.