HP M4555 Maintenance Kit Low, Cannot reset

[SteveMcIT]

I have replaced the maintenance kit and run the Admin maintenance kit ritual six times on this M4555, and it says it saved the settings, but it always ends up with the same "Maintenance Kit Very Low" message. Any ideas on getting the maintenance kit reset to stick?

UPDATE 5/20/20: The problem was that somehow the Maintenance Kit Interval value was 1 instead of 225,000. After editing the value through the Maintenance option on the control panel, saving the new value, and rebooting the printer, the error is gone. A huge thank you to our vendor tech for chasing this down through some of his part suppliers who actually had run into this before. I am not sure I can post their names, so I will leave it at that. Thanks for all the other input I got from the HP Community as well! 

[Valsimot]

Print yourself supplies status page and check both statuses of a maintenance kit and ADF maintenance kit.

[Repairatrooper]

We did have issues with some older firmware revisions that would not hold the reset and revert back to the maintenance message.  In some cases we had to manually edit the page count for the PM kit

[SteveMcIT]

Thanks for the suggestion, but the ADF kit is 100%.

[SteveMcIT]

The unit already the latest firmware, but I reloaded it anyway hoping that might resolve the issue. It did not. So far I have rebooted it several times, run the administrative reset routine 8 times, and now reloaded the latest firmware.

I did just talk to a regional repair tech for our vendor, and he said "sometimes a fuse blows in the replacement fuser", so he is having a second fuser sent to me. I have never heard of that happening, but maybe that is the issue. We will see. 

[Valsimot]

The fuse in a new replacement fuser is used to blow out and to automatically reset maintenance count on printers that don't have a manual reset.

The M4555 has manual maintenance count reset from users menu, it doesn't use a fuse to reset. Not sure will a new fuser fix this. If a new fuser doesn't help you will need as mentioned above manually set fuser maintenance count to 0 from the service menu 

[SteveMcIT]

Yeah, I tried resetting the maintenance count manually in the service menu, and rebooted the MFP, but still have the same error message, even though the maintenance count is now zero. Thanks for the information on the fuse reset. I was not aware of that.

[Repairatrooper]

I did some more checking as I remember seeing a tech docu about a similar issue on a different model. In that case it was the ADF maintenance message that would not clear. The resolution was to perform a partial clean through the preboot menu as there was a corruption in the firmware that simply updating the firmware would not resolve.

[tonerspills]

I was mistaken on these fusers having the quick blow fuse. That's some of the M600 / M800 and newer devices.

I've reviewed the service manual and theory of operation several times now to see if we can identify exactly where that maintenance kit counter is stored on the M4555. I cannot. I'm going to make a guess that it's saved in some type of NVRAM, similar to some other configurable device settings. It could be the HDD, but since these settings are also retained on devices without a HDD or SSD I base that upon the idea that you can unplug the device, but those levels are retained. The fuser temperature and operation are controlled by the DC controller. So it is possible there may be a memory chip on the DC controller itself, but I would think the levels would have to be written / adjusted by the formatter.

You should be able to continue printing to the device even if the maintenance counter hits zero%

admin menu / supply setting / maintenance kit / very low settings / select "continue" not stop or prompt to continue

You could try and NVRAM reset, which will basically wipe the device and all its settings.

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[SteveMcIT]

Please see the solution on the original post as an UPDATE.