I experienced this exact problem today after upgrading the fw on a CM4540. I suspect that the fw upgrade is buggy and sent a bad bit down to the DC Controller. I already replaced the formatter and HDD to no avail. I wiped the HDD and reinstalled the fw from thumbdrive to no avail. Replaced all the toner cartridges to no avail. The only thing that is left is the DC controller. I don't think the DC controller is cleaned when the disk is wiped. So, I'm going to replace the DC controller and will report back if it resolved the issue.
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