Firmware upgrade failed for Xerox Versalink c405 - write error 041-500 - printer bricked

[ag2000]

Final report - I was able to update really buggy bridge version to the latest service pack (PL-R6).

As a reminder, the problems with bridge version were:
1. Unable to do remote update (or even check for the latest version from the printer or web interface)
2. Problem with tray selection - while I had correct (letter) size paper loaded and registered it would complain that I do not have correct size. This issue was happening with any Windows machine where I installed proper driver from Xerox site. (Airprint worked fine)

3. Problem with firmware upgrade.
- Firmware upgrade tool for windows simply would not detect printer on the network ( even after entering proper printer IP address.
- Upgrade from web interface via network bricked the printer.

Therefore, my last upgrade I did with firmware upgrade tool via USB cable. It worked like a charm, took about 5-7 min to upgrade.

And finally all other problems mentioned above seem to be fully resolved.

It is too bad that Xerox does not print these instructions on their support website, but I am glad that these forums exist, have very helpful participants and have high search index on Google.

[ag2000]

Quick update : I was able to find the answer to my previous question in this video https://youtu.be/zFJjVKjJqiM
I do not know the language of the video but someone explained in the comments that you have to press certain part of the screen - specifically in the AL and BO in the “speciAL BOot” message, while pressing home button. Then dial pad shows up and everything works. I chose to reinstall bridge version first, and everything works now! Next I will try to upgrade again to the latest version, this time via USB port - and will report if I had any issues.

[ag2000]

Many thanks for the detailed instructions! I tried to follow them and I am able to get to the first “special boot mode” which was described in more details in my original post, but unable to get to the dial screen. When I press any part of the screen+ home button - nothing happens. Only when I press lower right corner of the special boot mode screen showing “V1” + press home button - then it switches to “inspection mode” but nothing else happens after that. I can see that USB stick lights up so looks like it tries to read it, but no result. Can you please provide more details which part of the screen do you press?

[TDS]

Okay, here's how to fix this. You'll need the latest firmware for your printer model. You can download it from the support page. Extract it to your computer. You'll need the *.bin file in the zip you downloaded. You'll also need an empty FAT32 formatted USB drive.

USE THESE INSTRUCTIONS AT YOUR OWN RISK!

Updating Firmware on VersaLink B and C Series Printers using AltBoot

1. Download the latest firmware for your printer model from Xerox Support.
2. Locate an empty FAT32 formatted USB thumb drive.

Prepare the USB Drive

1. Create a folder named DWLD in the root of the USB drive.
2. Extract the firmware files from the *.zip file you downloaded from Xerox Support.
3. Copy the *.bin file into the DWLD folder on your USB drive.
4. Safely Remove the USB drive.

Boot the Printer using the AltBoot Procedure to Update Firmware

1. If the printer is powered on, press and hold the power button until the printer shuts down completely.
2. Insert the USB drive into the USB slot on the front of the printer.
3. Press and Hold the Home button and Power simultaneously and continue holding until the printer displays Special Boot Menu.
4. Tap and hold Special Boot Menu on the screen and press the Home button simultaneously until a dial screen appears.
5. On the dial screen, enter 6789# and the printer will display Special Boot Menu 1/3.
6. Tap Download Mode and then tap Yes on the confirmation screen to reboot the printer.
7. The printer will reboot and install the firmware file frome the USB drive. This process may take several minutes and the printer may reboot several times. You MUST allow this process to finish completely without interrupting it.
8. The printer will print a Software Upgrade report when the firmware update is complete.
9. You may remove the USB drive and use your printer.

You're welcome.

[TDS]

Anyone care to respond to this? I'm having this identical issue after the automated firmware update failed from the control panel. Same exact error.

I attempted to use the Windows firmware utility to install the latest firmware service pack, but it says that "the firmware selected doesn't match with the device" despite it being the correct one.

[ag2000]

DUe to various issues with the printer including inability to do remote update (connectivity problems) and failed print jobs due to incorrect default tray selection - I have decided to upgrade the firmware to the latest available version 68.67.91.  The instructions said to install bridge version 68.59.1 first.  I checked the existing version using web interface and it was showing 68.59.1, so I started the upgrade to 68.67.91 via Web Interface.  AFter the upgrade started, it was stuck at 12% for some time, then immediately moved to 75%, stuck again then ended up with the message "write error 041-500" on the red screen. I waited and nothing else happened within one hour. Then I tried to reboot the printer and now it comes to the blank screen instead of control panel, and I am unable to connect to it via Web Interface. ALso, connection via USB port no longer works as well. I tried to restart the printer, and one or two times it said "checking file system" but would get stuck at that message. I also noticed that holding power button and home button at the same time while trying to turn on the printer brings it to a "special boot menu"  offering "HDD initialize mode" and "Storage device initialize mode" but one of the modes does nothing and second mode shows "file system checking" screen which does not do anything else - even overnight there is no change to the screen.  Can Xerox post instructions what have to be done in this case? 

I saw similar thread where Xerox employees offered to provide instructions by email - can they be posted here?

Also, is it possible to explain the "Special boot menu" for Xerox Versalink c405 as I could not find the explanation anywhere....