Welcoming the Newer Models to the 7425 Style

Xerox WC 7425, 7428 & 7435 styles, 7525, 7535, 7545, & 7556 styles, and
7830, 7835, 7845, & 7855 styles)
When new models follow older models footprints, its a huge help. It helps reduce the
learning curve to work on a machine that already feels familiar. Of course there are always
subtle differences to be found among the newcomersthings worth knowing about which
can save you plenty of head scratching time. This month, lets have a look at the basics of
the diagnostics for the newer 7525 and 7830 families in comparison to the first batch of
models (7425-7435) which we had covered in ENX back in the summer and autumn of
2013.
First off, lets talk about the differences between the supplies. The supplies changed
significantly from the 74xx family that started this style out. The toner cartridges dont fit
back and forth and in fact there was a change in the formula in the toners that came with
the newer models. The drum cartridges look nearly identical and share a lot of the same
or very similar parts, but there are actually two important differencesthe 7425 version
(013R00647) naturally had a different CRUM chip (Customer Replaceable Unit Monitor)
compared to the 7525 / 7830 version (013R00662). Second, there is an indexing hole in the
front metal plate behind the front cover that has a different diameter when you compare
the two. This causes trouble if you try to install a 7425 in a 7525 or vice versa.
The fuser modules look similar at first glance, but are almost nothing alike. The newer
models utilize altogether new technology (induction heating). The older 7425 fusers had a
traditional rigid heat roll and a film sleeve over a pressure pad. The new models instead of
having a familiar heat roll have a heat belt, like a semi-rigid sleeve with a gear glued to the
end, and conversely, it has a traditional looking pressure roller.
In addition, the document feeders and the cleaning assembly have changed as well, but
the second BTR (transfer roller) is the same, as are the paper feed rolls.
Now onto something rather fascinating. The fault codes, which were published in ENX in
the August 2013 issue, turn out to be very similar codes for the most part in the newer
models, EXCEPT that they changed the first digit in every code from a 0 to a 3. For
example, in the 7425 a fault code of 092-312 means ATC (Automatic Toner Concentration)
Failure for Yellow, and in the newer book the same fault would appear as a 392-312. There
was one important fault code I actually could not find in the newer service manual to my

surprise. I saw no fault code clearly meaning IBT Belt Home Position Sensor Failure.
Usually that is a fail which locks up a machine, but in the 75xx book, this code either hid
extremely well, or simply wasnt there to be found. Feels like I am missing something.
Now for getting into the Diagnostic Mode (CE Mode)
This remains almost the same as it was for the 7425 family. Press and hold the 0 button
for 5 seconds, then while youre still holding 0, press Start. This will bring up the CE
Passcode screen, enter 6789 at the prompt and touch Confirm. Now on the newer
models, that is all there is to ityoud already be in the right screenbut on the older
machines, youd have to press the Machine Status button and then select Tools. Next you
will choose System Settings. Now in the Group column, choose Common Service
Settings and in the Features column, scroll down and choose Maintenance / Diagnostics.
The diagnostic menu has changed for the new models. Here are the tabs which are
available on the newer models:

Service Info: This is the default tab. Here youll find things like Fault
History, Serial Number, Product Code, IP address, and CRU / HFSI
(consumable counter resets).

Diagnostics: This tab has choices that include the Component Control
and Test Pattern Prints.

Adjustments: Here you will find many of the diagnostic functions

including the NVM Read / Write (memory adjustments), Registration, and
Tone-up / Tone-down.

Maintenance: This menu includes the Fault History for the machine.

Call Closeout: When closing out of diagnostics you can choose to keep
the fault history log or clear it. Usually it makes more sense to keep it, as it
is a good record of recent faults that were already repaired.Clearing some
fault codes (from Diagnostics)

Some faults must be cleared from diagnostics before the machine will
continue to work for you. For some you will need go into the Adjustments
(dC131: NVM Read / Write) and reset one of the values back to 0. Other
codes are reset from the dC135 CRU / HFSI screen. Got to love having two

acronyms in a row like that (CRU = Customer Replaceable Unit, and HFSI =
High Frequency Service Items).

When youre done, to exit diagnostics you can press and hold the 0 key
and press Start while youre still holding 0.

Fuser Heat Control problems (310-320, and 310-372): Read below

about how to reset NVM value 744-455 back to 0.

ATC Sensor failures (392-312 thru 392-315): Read about how to reset
NVM values (below), and refer to the following chart for which NVM settings
to set back to 0.

Fault Code

Color

NVM Settings to set to 0

392-312

Yellow

752-346 & 752-350

392-313

Magenta

752-347 & 752-351

392-314

Cyan

752-348 & 752-352

392-315

Black

752-349 & 752-353

How to use NVM Read / Write to clear any of the faults mentioned
above: From the Adjustments tab look for NVM Read / Write. Next enter the Chain /
Link code mentioned for each fault code above. The chain is the first part of the code
and the link is the second part of the code. For example if you want to go into 752-315,
the chain would be 752 and the link would be 315. When you put in an NVM code and
then select Confirm / Change on the touchscreen, the current value will show up. Enter a
0 in the New Value column and touch Save.

For faults 394-417 thru 493-422, these are CRU / HFSI faults,
which must be reset from the Service Info tab in diagnostics. Read
below about how to reset HFSI counters for the various consumable parts.

How to use CRU / HFSI to clear faults 394-417 thru 493-422: From the
diagnostic modes Service Info tab look for and choose CRU / HFSI Counters. This screen
lists the consumable items and displays Estimated Pages Remaining (or the percentage of
service life remaining). Choose the HFSI items chain / link you need to reset and select
Reset Counter.
Exiting Diagnostics:

When youre done, to exit diagnostics you can press and hold the 0 key and press Start
while youre still holding 0.
More work to be done exploring these new guys for sure, but hopefully if you were getting
familiar with the 7425 family and you run into one of the newer models, this gets you
started off in the right direction. Hope you all have a wonderful summer!