Having the same issue here. Could someone help me out? I swapped the HDD with another (used) one and am having the same exact behavior. Thanks!
You need, versions:
New boot SD card (from xerox)
Your own SD card not more than 8GB (better 4Gb 10 class), Linux command line, image of original boot SD card.
New or used HDD 500GB (better SSD min 128GB, bigger-better)
Just replace old with new and make ALTBOOT
Im having same issue updating from a really old firmware it does work via the web or forced USB stick method. Can anyone advise what is the exact procedure. USB method seems to cycle a few green start up screens then screen goes black and the LED flash green...I left this for couple of hours thinking it would be part of the procedure but no joy. Had to reboot and firmware was still the same.