Service History — Washington, DC — Page 2

Problem: HP Color LaserJet Enterprise MFP M577f reporting a persistent 'flatbed cover open' error, preventing normal copy and scan operations.

Solution: Diagnosed faulty ADF sensor flag with a worn, non-orderable return spring. Replaced the flatbed scanner assembly (part B5L46-67904). Post-replacement calibration failed; technician identified the ADF assembly was unevenly secured — taped firmly on the left and loose on the right — causing a right-si

Problem: Zebra ZT610 (ZT61042-T010100Z) in Bethesda, MD reported rollers stuck and printer unable to produce output.

Solution: Diagnosed a ribbon error caused by a connected laptop configured for thermal transfer mode on a direct thermal printer. Corrected the driver setting and confirmed normal print operation.

Problem: HP LaserJet M607 reported printing issues at page count 106,609. Vehicle labels were tearing inside the printer and separating from their backing paper during the print cycle.

Solution: Technician replaced the fuser, tray 2 pickup roller, and separation roller assembly. Inspection revealed the original fuser had a torn Mylar heat roller sleeve. A customer-supplied interim fuser was removed and returned to its original unit on-site. New fuser core installed; defective core retained

Problem: Zebra 105SL thermal printer in Arlington, VA was flagged for preventive maintenance service.

Solution: Technician performed a PM25-level preventive maintenance service on the Zebra 105SL (model 10500-3001-2000).

Problem: Lexmark MS821 laser printer in Alexandria, VA was due for preventive maintenance and required a replacement maintenance kit.

Solution: Sourced and supplied an OEM maintenance kit for the Lexmark MS821. Part was shipped directly to the customer's location for installation.

Problem: Customer required a new HP LaserJet Enterprise M635h to replace an aging HP LaserJet M3035 MFP, with a fax accessory card needed at the new location.

Solution: Technician installed the fax card into the HP LJ Enterprise M635h, transferred network configuration from the retired M3035 MFP (retaining the existing IP address), coordinated with the customer's IT team for remote driver and scan-to-email setup, and retired the old M3035 MFP.

Problem: HP LaserJet M607 producing poor-quality output on checks that were being rejected by the bank. Control panel display was also blank.

Solution: Installed replacement maintenance kit and reset the page count. Reseated control panel ribbon connections twice to restore display functionality. Output quality confirmed acceptable after testing.

Problem: HP Color LaserJet Enterprise MFP M880z presented for scheduled preventative maintenance (visit 2 of 4) at approximately 700,031 total pages.

Solution: Technician performed scheduled preventative maintenance on the HP Color LaserJet Enterprise MFP M880z at 700,031 pages. Unit was cleaned, inspected, and tested to verify proper operation before closeout.

Problem: Nine Zebra ZT421 thermal label printers at a Greenbelt, MD facility were due for quarterly preventive maintenance. Several units were also flagged for ribbon compatibility issues causing print defects.

Solution: Technician cleaned, calibrated, and inspected nine Zebra ZT421 thermal printers. Findings documented for customer action included incorrect ribbon type and oversized ribbon width on multiple units — one producing diagonal voids — and a worn ribbon spindle (P1058930-045) on one unit requiring replace

Problem: Zebra ZM400 industrial thermal printer reported a motor issue affecting normal operation.

Solution: Technician identified a loose drive motor and tightened the motor-to-belt connection. Unit was tested and confirmed operational.

Problem: HP LaserJet M607 repeatedly jamming in the tray area.

Solution: Installed a replacement maintenance kit on the HP LaserJet M607, cleaned internal paper path components, and tested to confirm jam-free operation.

Problem: HP Color LaserJet M680 reported a tray overfull error despite tray 2 being empty, indicating a faulty or obstructed tray sensor.

Solution: Removed torn paper and a fingertip glove lodged in the tray 2 feed assembly, clearing the false overfull condition. Replaced tray 2 and tray 3 pickup rollers using customer-supplied stock. Cleaned the machine and tested to confirm normal operation.

Problem: Lexmark CX510de displayed persistent error code 82.31 ('Replace waste toner bottle') even after the customer installed two separate Lexmark OEM waste toner bottles.

Solution: Technician diagnosed a failed controller card (40X7806) and defective waste toner bottle sensor assembly (40X7046) as the root cause of the false 82.31 error. Both components were replaced, clearing the error. A faulty black developer unit (700D1G) was then identified causing image fading and replac

Problem: HP LaserJet MFP M528 reported error code 98.0.0.0, indicating a hard drive failure.

Solution: Technician replaced the failed hard drive and reloaded firmware on the HP LaserJet MFP M528. Fax and host settings were reconfigured and the unit was tested to confirm full operation.

Problem: Customer in Alexandria, VA required a new HP LaserJet Pro M426fdw MFP, additional paper tray, and printer stand.

Solution: Sourced and fulfilled an HP LaserJet Pro M426fdw MFP with an extra paper tray and printer stand; all three items shipped separately to the customer.

Problem: A College Park, MD customer required a new Lexmark MS621dn monochrome laser printer with two additional paper trays.

Solution: Sourced and delivered a Lexmark MS621dn along with two optional paper tray accessories to the customer site in College Park, MD.

Problem: Zebra GX430t thermal label printer in Reston, VA was due for scheduled preventive maintenance.

Solution: Performed preventive maintenance on the Zebra GX430t at 109,996 inches of use. Cleaned internal components and verified printer configuration.

Problem: Zebra ZT410 thermal printer in Alexandria, VA displayed 'Alert Ribbon Out' and 'Printer Paused' errors and would not print.

Solution: Technician performed a media/ribbon calibration, restoring print function. The unit repeatedly lost ribbon calibration — indicative of a failing ribbon sensor or main logic board. Given the repair cost, the customer elected to pursue a warranty swap.

Problem: HP DesignJet Z6600 wide-format plotter reported magenta ink bleeding on output. Investigation revealed a faulty printhead with excess ink escaping while seated, compounded by an incompatible paper type selection for canvas textured media.

Solution: Replaced carriage assembly (F2S71-67002) and belt/tensioner assembly (CQ111-67003), correcting an inverted tensioner on the replacement belt. Swapped a defective photo black/grey printhead the customer had on hand. Performed carriage and belt life count reset via service mode, printhead alignment, l

Problem: Zebra 105SL Plus thermal printer in Bowie, MD required replacement parts to return the unit to service.

Solution: Replacement belt, platen roller, and printhead ordered and shipped directly to the customer site pending vendor shipping confirmation.

Problem: Zebra ZT510 203DPI industrial thermal printer was due for scheduled quarterly preventive maintenance at a Fairfax, VA facility.

Solution: Cleaned printhead and platen roller, inspected drive belts and gears — all components in good condition. Quarterly PM completed per maintenance schedule.

Problem: Zebra 110Xi3 thermal printer reported with multiple issues at a Gaithersburg, MD facility.

Solution: Service call was cancelled by the customer prior to technician dispatch; no on-site work was performed.

Problem: Lexmark MB2546 in Falls Church, VA required a maintenance kit replacement.

Solution: Maintenance kit was ordered and sourced for the Lexmark MB2546. Upon part receipt, the technician completed the maintenance kit installation.

Problem: Zebra 220xi4 industrial thermal printer reported with a failed printhead requiring replacement — one of multiple units in the facility needing service.

Solution: Replaced the printhead on the Zebra 220xi4. Following installation, the printer continued to wrinkle the ribbon; the customer was advised this issue fell outside the current scope of work and the call was closed accordingly.

Problem: Zebra ZD620 thermal printer presented with a non-functional control panel display — backlight active but no screen output — requiring PM24 preventive maintenance service.

Solution: Technician replaced the control panel PCBA with LCD (P1080383-241), platen roller, and cutter assembly using donor parts. Unit was tested and confirmed operational post-repair.

Problem: HP LaserJet M608N experiencing continuous paper jams originating from the bottom tray.

Solution: Replaced the fuser maintenance kit on the HP LaserJet M608N (page count 458,278). Cleaned internal paper path components and tested to confirm jam-free operation.

Problem: A Rockville, MD customer needed to replace two Zebra ZM400 thermal label printers and requested sourcing of refurbished units.

Solution: Two refurbished Zebra ZM400 thermal printers were procured and drop-shipped directly to the customer's facility for self-installation.

Problem: Zebra ZT510 thermal printer reporting a media/ribbon calibration error, preventing normal label printing operations.

Solution: Technician resolved the calibration error by tightening the drive gear assembly and making mechanical adjustments. Main board and media sensor in the rack guide area were identified as components requiring attention.

Problem: HP LaserJet P4015 presented with multiple faults: fuser irregularities, worn rollers, a broken cassette tray guide, a missing roller flap spring, and persistent front-end paper jams near the registration assembly.

Solution: Technician located and reseated the roller flap spring found inside the tray. Debris (food crumbs) packed beneath the registration assembly was cleared. Registration assembly, feed roller assembly, and solenoid were fully disassembled and inspected — no warped or broken components found. Tested with

Problem: Zebra 140xi4 thermal printer in College Park, MD reported partial print output — only a portion of each label was printing.

Solution: Diagnosed a defective printhead as the cause of the partial print issue. Replaced the printhead under warranty and tested the unit to confirm full-width label output was restored.

Problem: Zebra 105SL thermal printer producing white and dark lines in printed output.

Solution: Removed and flattened the ribbon strip plate, then reinstalled. Replaced a locked-down toggle with two new toggles. Post-repair test confirmed clean print output with no horizontal line defects.

Problem: HP LaserJet M501dn in College Park, MD was multi-feeding from Tray 2, pulling multiple sheets simultaneously instead of single sheets.

Solution: Replaced the Tray 2 roller kit on the HP LaserJet M501dn, cleaned the paper path, and tested feed performance to confirm single-sheet pickup was restored.

Problem: HP LaserJet M401dne reported for service with approximately 32,907 pages on the counter.

Solution: Technician performed a thorough internal cleaning of the HP LaserJet M401dne and tested the unit; print quality confirmed within acceptable margins.

Problem: HP LaserJet M521 producing vertical lines along the side of printed pages, indicating fuser or maintenance kit wear.

Solution: Installed a full maintenance kit on the HP LaserJet M521. The initial replacement fuser triggered a 'Jam in output bin — open rear door' error; a second fuser was sourced and installed, clearing the fault. Printer cleaned and tested to confirm clean output.

Problem: Zebra ZT510 thermal printer in Bowie, MD reported small labels shifting on 2 of 3 units.

Solution: Inspection revealed a missing media guide plate (P1053360-015) causing label misalignment. The replacement media guide plate was sourced, installed, and tested to restore consistent label registration.

Problem: HP LaserJet MFP M525 repeatedly returning error code 52.00.00 (laser/scanner fault) after power cycling, with print lines on output and paper feed issues across all three trays.

Solution: Technician cleaned the scanner glass, adjusted tray guides on all three trays to correct letter-size alignment, and cycled power to restore operation. Laser/scanner assembly (RM1-6322-000), tray roller (RM1-6323-000CN), and separation pad (RM1-6303-000CN) were replaced. Unit tested and confirmed ope

Problem: Zebra ZT510 thermal printer in Falls Church, VA reported a ribbon/media sensing error, preventing normal print operations.

Solution: The customer power cycled the unit and the sensing error self-cleared. No on-site visit was required; the call was closed after no further contact was received.

Problem: HP Color LaserJet M551 in Laurel, MD was failing to pick up paper from Tray 2.

Solution: Technician replaced the Tray 2 separation roller (RM1-8129) and pickup roller (RM1-8131), then cleaned the printer and verified consistent paper feed through functional testing.

Problem: HP LaserJet M604 presented with a high page count requiring a scheduled maintenance kit replacement.

Solution: Installed a maintenance kit on the HP LaserJet M604 and reset the page count. Unit was tested and confirmed operational following the service.

Problem: Zebra 105SL (model 10500-3001-2000) in Manassas, VA required a scheduled PM32 preventive maintenance service with multiple component replacements identified.

Solution: Replaced main board (34901-020M), ribbon sensor (G46665M), toggle assembly (35099M), and ribbon roller kit (P1006101). All parts were installed and tested to confirm full operation.

Problem: HP Color LaserJet M553 reported producing loud noise during operation.

Solution: Technician diagnosed the noise to a failing transfer belt. An OEM replacement transfer belt was sourced and shipped to the Frederick, MD location for installation.

Problem: Zebra ZT410 thermal printer in Alexandria, VA not rewinding media; insufficient rewind tension reported across all four units.

Solution: Diagnosed rewind tension fault on Zebra ZT410. Printer operates under PLC control; resolution requires a coordinated on-site visit with the customer's PLC programmer and a certified technician to recalibrate tension settings.

Problem: Zebra 110Xi4 thermal printer was failing to keep all text within a single label, causing print registration issues.

Solution: Technician inspected, cleaned, and manually calibrated the Zebra 110Xi4. Found the media sensor positioned at the very edge of the label stock; adjusted it inward to improve media detection. Verified fix with approximately 100 test labels printed without further registration errors.

Problem: Customer in Herndon, VA requested procurement of a new HP Color LaserJet MFP M479fdw unit.

Solution: New HP CLJ M479fdw MFP was ordered on the customer's behalf; unit was placed on backorder and the order was subsequently cancelled before fulfillment.

Problem: HP LaserJet MFP M830 reported sticky keyboard buttons preventing normal operation.

Solution: Diagnosed keyboard input failure on HP LaserJet MFP M830. Replaced defective keyboard assembly, cleaned the unit, and verified full functionality through testing.

Problem: HP DesignJet 800 42" producing a faint blue cast across all prints, indicating printhead failure.

Solution: Cleaned carriage contacts. Customer-supplied replacement printheads were from a defective HP manufacturing batch requiring a firmware update; the connected Windows 98/2000 PC made firmware updates too risky. Technician mixed verified current-stock printheads with compatible units to restore output.

Problem: Zebra ZT411 thermal printer in Manassas, VA was producing faint print output and labels were jamming during the print cycle.

Solution: Technician reduced toggle pressure, halved print speed, and doubled darkness settings. Printhead and drive belt inspected and confirmed serviceable. Print quality and label feed restored.

Problem: Zebra ZT510 203 dpi thermal printer was due for its second of four scheduled quarterly preventive maintenance visits at an Alexandria, VA facility.

Solution: Technician cleaned the printhead, inspected drive gears and belt — all found in good condition — and verified print quality before completing the quarterly PM.

Problem: Brother MFC-L8905CDW laser printer in Laurel, MD was not powering on.

Solution: Technician was dispatched to diagnose a no-power condition on a Brother MFC-L8905CDW. Service manual for the MFC-8900 series was referenced for the repair procedure.

Problem: HP DesignJet T120 24" plotter in Frederick, MD required a firmware update; the Ethernet cable clip was broken, intermittently disrupting network connectivity.

Solution: Confirmed the plotter's internal auto-update incorrectly reported firmware as current. Downloaded the correct firmware from HP.com to the customer's computer and executed the update via HP utility. Temporarily secured the damaged Ethernet cable and advised replacement with a new 15–20 ft patch cable