HP DeskJet 2540 Cartridge Extension Kit: Why Is the Black Ink Not Printing?

Question:
I purchased the BCH Technologies cartridge extender kit for my HP DeskJet 2540 printer and modified my cartridges by replacing the front and internal sponges as shown in your YouTube videos. The color prints look perfect, but the black ink doesn't print at all. I followed all the steps correctly-why isn't the black ink working?

Answer:

Now, let's go over the possible causes for your HP DeskJet 2540's black ink not printing issue after installing the cartridge extender kit.

1. Air Trapped Inside the Black Cartridge

One of the most common reasons black ink fails to print after refilling or modification is air trapped inside the cartridge. When you replace the sponge or extend the cartridge, it's easy for air pockets to form inside the ink chamber or printhead. Air prevents the ink from flowing smoothly through the nozzle.

Fix:

• Use a syringe with a needle to gently draw a small amount of ink from the outlet (the small hole at the bottom of the cartridge).

• If you hear a "hiss" before ink starts flowing, that means you're releasing trapped air.

• Once ink begins to flow steadily into the syringe, reinstall the cartridge and try a nozzle cleaning cycle.

2. Dried or Clogged Printhead

When modifying or refilling cartridges, the printhead (the metallic section with small nozzles at the bottom) may dry out if exposed to air for too long. Dried pigment ink, especially from black cartridges, can easily block the nozzles.

Fix:

• Remove the black cartridge and soak just the printhead area in a shallow dish of warm, distilled water for about 10-15 minutes.

• You can also use BCH's Printhead Cleaning Solution for more effective results.

• After soaking, gently pat the printhead dry with a lint-free cloth and reinstall the cartridge. Run a few cleaning cycles from your printer's maintenance menu.

If you notice faint black streaks or gaps in your test print, repeat the cleaning process until the lines appear solid.

3. Electrical Contact Issues

Sometimes, even if the ink and printhead are fine, poor contact between the cartridge and printer can stop it from working. This often happens after modification when small ink splatters or residues build up around the contact area.

Fix:

• Turn off your printer and remove the cartridge.

• Use a soft, lint-free cloth lightly dampened with isopropyl alcohol to clean the gold electrical contacts on both the cartridge and printer carriage.

• Let them dry completely before reinserting the cartridge.

4. Cartridge Memory Lock (HP Tracking ID)

HP printers, including the DeskJet 2540, keep track of cartridge ID codes. If the same cartridge is refilled and reinserted, the printer still remembers it as "empty." While this doesn't stop color cartridges from printing, it can sometimes prevent the black one from firing if the chip data is mismatched or corrupted during modification.

Fix:
The workaround is to rotate between two or more cartridges. Use a second cartridge (even if it's empty) and print a page with it installed. Then, swap back to your refilled one. This trick sometimes clears the printer's memory and allows it to recognize the cartridge as "new."

5. Printhead Burnout or Electrical Failure

If none of the above steps solve the issue, it's possible that the printhead has burned out. The black ink in HP cartridges is pigment-based and can dry quickly. If the printer attempts to print while the nozzle is dry, electrical overheating can damage the internal resistor-permanently disabling that nozzle array.

In this case, you'll need to replace the black cartridge entirely. Once replaced, keep it moist by printing regularly or sealing it in an airtight bag when not in use.

Addressing printer issues can be a complicated affair due to the hands-on nature of the problems. Therefore, we're unable to provide remote troubleshooting, suggestions, or repair support. We do, however, offer in-person evaluations and repairs through our local diagnostic facility (https://bchtechnologies.com/printer-repair-service). Due to high demand, we operate on a first-come, first-served basis, and it might take a few weeks before we can get your printer in for inspection. Our services can address either full printer repairs or specific part replacements, with clear instructions on how to proceed.

That said, we encourage exploring self-help resources online. You can start by visiting our YouTube channel (https://youtube.com/@bchtechnologies) and using the search icon next to the "About" tab to find tutorials tailored to your issue. With hundreds of videos produced over the years, this is often the quickest way to locate exactly what you need.

Thank you again for your trust, patience, and support. We truly appreciate your enthusiasm for BCH Technologies products and your dedication to mastering your printer's maintenance.