There have been some issues with the firmware causing some “unexplainable” happenings with the printer !! Unless you were aware the problem existed with the firmware, changing of the DC controller, power supply, fuser and even the formatter were all possible fixes to the problem the printer was exhibiting. Changing any of these components would not correct the issue. The printer would work fine form Tray 1 most all the time. A much different story from Tray 2 though. The printer will receive the data and display ‘PROCESSING’, the engine will cycle up like its going to pull paper and print the file….. then just stop!! Display will show IDLE with no error generated on the display or error log.  Turns out it was a problem with the printer’s firmware and fuser causing this to happen randomly. Upgrading the printer’s firmware to 4.060.7 or higher, and replacing the fuser at the same time will correct this “bug “ that has been in your printer making you scratch your head and wonder why is this happening? When the printer was first introduced in May of 2008 the first time “maintenance due” appeared on the display the reset procedure did not work as there was a glitch in the firmware. So an update of the firmware was required to remedy this issue as well.

This engine also has a redesigned fuser drive assembly, much like the 4200 series but not an orderable assembly like the now infamous “swing plate”. They have incorporated a much bigger, stronger looking gear to interconnect to the fuser assy. It should last longer than its predecessor’s swing plate assy. Time will tell if that’s the case. There is no part number for it listed in the parts manual. It is framed with about 6 gears, not captive so they will fall out when removed. The best chance of getting the pieces would be from a recycler of laser printer parts.

The removal procedure is very similar to the 4200 swing plate assembly – remove the top, left and right side covers, formatter, right side rear cassette guide, power supply and disconnect the left side fan and environmental sensor. Once you get this far in you will find a frame piece which spans the printer which will have to be removed to gain  access to the screws which hold the bracket in place, which house the gears. Removal is not impossible, a small Philips screwdriver with a good end will suffice. If you have trouble removing, try to tighten a bit first to crack the seal, so as not to strip the screw head!! Once you have this frame piece off there is one gear that will need to be removed to get at the last of 4 screws that hold the “swing plate frame” in place. These are the black headed screws which do not seem to be very strong so again be careful when removing them.

Tray 1 is a trouble spot as the hinges that attach the multipurpose tray to the feed assembly get “mysteriously” broken off. The tray is bumped into or forced shut causing the attaching arms to break off or the teeth on the end sheer off. No replacement pieces are available to repair the assembly. Your options are again a recycler of printer parts or the purchase of a new Tray 1 paper feed assembly. As time goes by maybe these parts will become available?

This P4015 series of printers has some issues with toner also. The printer works fine on plain text, crisp clear and dark. After the cartridge has had some usage, heavy graphics give some troubles as the full blacks are not strong and fading or even graying occurs. Replacing the transfer roller, power supply or the laser scanner, the usual suspects have little or no effect. A new toner cartridge is your best bet for printing graphics.