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Lexmark CX825, CX860, XC8155, XC8160, Service Manual & Parts List (Edition manual: January 2016)

Service Manual & Parts List Lexmark CX825, CX860, XC8155, XC8160;
This service manual, is the full Lexmark CX825, CX860, XC8155, XC8160 Service Repair Manual.
This manual, Lexmark CX825, CX860, XC8155, XC8160, is in the PDF format and have detailed Diagrams, pictures and full procedures to diagnose and repair your Lexmark CX825, CX860, XC8155, XC8160 copier.
You can print, zoom or read any diagram, picture or page from this Service Manual. Every chapter on this manual is fully detailed and contain all the simulation codes, trouble codes, maintenance procedures, reset procedures, diagnose procedures of Lexmark CX825, CX860, XC8155, XC8160 photocopier. You can find easily everything what do you need.
To see what contain, please read table of contents:

Edition notice
Notices and safety information
Laser notice
Avis relatif a l'utilisation du laser
Notificacio del laser
Aviso de laser
Aviso sobre laser
Avvertenze sui prodotti laser
Meddelande om laser
Safety information
Consignes de securite
Informacio de seguretat
Informacion de seguridad
Informacoes sobre seguranca
Informatie over veiligheid
Informazioni sulla sicurezza

General caution statements

Printer model configurations
Finding the serial number
Paper and specialty media guide
Supported paper sizes, types, and weights
Paper guidelines
Using specialty media
Data security notice
Tools required for service

Troubleshooting overview
Performing the initial troubleshooting check
Fixing print quality issues
Initial print quality check
Blank or white pages, or one color missing check
Dark print check
Ghost images check
Gray or colored background check
Horizontal dark lines check
Light print check
Mottled print and dots check
Print crooked or skewed check
Solid color or black images check
Text or images cut off check
Toner easily rubs off check
Uneven print density check
Vertical dark lines or streaks check
Vertical white lines or voids check
Blurred print or misaligned color check
Image banding check
Image void (process direction) check
Random marks check
Repeating defects check
Fixing scan quality issues
Dark image quality (using the ADF or scanner) check
Vertical lines (process direction using the ADF) check
Spots (using the flatbed scanner) check
ADF skew check
Media damage (using the ADF) check
Wavy edge (ADF 2nd side scan) service check
Paper jams
Avoiding jams
Identifying jam locations
Paper jam in trays
Paper jam in the multipurpose feeder
Paper jam in the automatic document feeder
Paper jam in the standard bin
Paper jam in door B
Paper jam in the finisher bin
Staple jam in door G
Paper jam in door K
Paper jam in door J
Paper jam in door N
Paper jam in door L
Paper jam in the staple finisher bin
Staple jam in door J
200 paper jams
201-202 paper jams
212 paper jams
213 paper jams
221-230 paper jams
231 paper jams
232 paper jams
240 paper jams
241 paper jams
242 paper jams
243 paper jams
244 paper jams
245 paper jams
280 paper jams
281 paper jams
282 paper jams
283 paper jams
284 paper jams
288-289 paper jams
Procedure before starting the MSHPF service checks
Procedure before starting the mailbox service checks
40y paper jams
41y paper jams
42y paper jams
43y paper jams
45y paper jams
46y paper jams
47y paper jams
48y paper jams
User attendance messages
User attendance messages (0-99)
Cartridge or photoconductor error service check
Mismatched paper size service check
Insufficient memory service check
Complex page service check
PPDS font error service check
Flash memory failure service check
Insufficient flash memory service check
Network service check
Unsupported internal option service check
Disabled port service check
Excess options service check
MSHPF configuration error service check
Incompatible hardware option service check
Hard disk failure service check
Maintenance kit service check
MSHPF staple cartridge error service check
Printer hardware errors
10y errors
110 errors
12y errors
13y errors
14y errors
15y errors
160-161 errors
162-165 errors
166-169 errors
17y errors
6yy errors
Procedure before starting the 9yy service checks
900 errors
98y errors
Output option hardware errors
302 and 323 errors
36y errors
374-383 errors
Service option software error service check
Printer symptoms
Multiposition staple, hole punch finisher symptoms
2-bin mailbox symptoms
Input option symptoms
Staple finisher symptoms

Understanding the printer control panel
Using the control panel
Understanding the status of the power button and indicator light
Using the home screen
Printing a menu settings page
Menus list
Diagnostics menu
Entering the Diagnostics menu
Event Log
Advanced Print Quality Samples
Input tray quick print
Printer Setup
Printer diagnostics and adjustments
Additional input tray diagnostics
Output device diagnostics
Scanner diagnostics
Entering invalid engine mode

Removal precautions
Data security notice
Handling ESD-sensitive parts
Controller board/control panel replacement
Restoring the printer configuration after replacing the controller board
Restoring solutions, licenses, and configuration settings
Updating the printer firmware
Backing up eSF solutions and settings
Disconnecting ribbon cables
ADF skew adjustment (front side)
ADF skew adjustment (back side)
ADF skew adjustment (deskew roller)
Printhead alignment adjustment
Registration adjustment
Color alignment adjustment
MSHPF tamper alignment adjustment
Removal procedures
Left side removals
Left upper cover removal
Fuser removal
Transfer roller removal
Duplex drive gears removal
Duplex release latch removal
Deskew roller sensor guide removal
Plastic connector cover removal
Metal connector cover removal
Left door, duplex, and MPF removal
MPF pick roller removal
MPF pick guide removal
MPF tray stop removal
Redrive removal
Redrive gear removal
Sensor (input) removal
Sensor (MPF/pass-through) with deflector removal
Reference edge motor gearbox removal
Isolation roller gear removal
Right side removals
Vent cover removal
Column outer cover removal
Right cover removal
Column inner cover removal
Printhead fan removal
Printhead removal
Motor (printhead wiper) removal
Front side removals
Keyboard attach cover removal
Control panel display removal
Control panel removal
Control panel button kit removal
Developer unit and photoconductor unit removal
Front column upper cover removal
Inner upper cover removal
Inner lower cover removal
Front door removal
Transfer belt removal
Pick roller removal
Separator pad removal
Door rod cover removal
Sensor (door interlock) removal
HVPS fan removal
Main HVPS removal
PC unit/developer door removal
Lower front cover removal
Paper feeder removal
Sensor (auto alignment) removal
Sensor (TPS) removal
TPS sensor wiper removal
Developer/PC unit CMY wiper rail removal
Developer/PC unit K wiper rail removal
Rear side removals
Controller board cover removal
Rear lower cover removal
Rear upper cover removal
Rear left cover removal
Charge roller HVPS removal
Controller board SIM removal
Controller board removal
Main fan removal
LVPS removal
LVPS cage removal
Weather station removal
Controller board cage removal
Toner add motor gearbox (K, C, and M) removal
Toner add motor gearbox (Y) removal
Main fan duct removal
EP, developer, toner add gearbox removal
Fuser/transfer belt motor gearbox removal
Waste toner gear removal
Toner supply actuator removal
Smart chip interface board removal
Toner cartridge contact removal
Toner add tube removal
Top side removals
Top cover removal
Standard bin cover removal
Sensor cover removal
ADF and flatbed removals
ADF pick roller cover removal
ADF pick roller removal
ADF feed belt removal
ADF rear cover removal
ADF removal
ADF controller board removal
ADF tray removal
ADF front cover removal
ADF bottom door removal
Top interlock actuator removal
ADF front drive train removal
Motor (ADF) removal
Motor (ADF calibration roller) removal
ADF top door with hinge removal
ADF top door cover removal
ADF rear drive gears removal
Bottom interlock actuator removal
ADF separator roller removal
Input guide removal
Sensor (ADF multifeed receiver) removal
Sensor (ADF multifeed transmitter) removal
CCDM (ADF) removal
ADF media exit actuator removal
Sensor (ADF 2nd scan) removal
Flatbed scanner front upper cover removal
Flatbed scanner left cover removal
Flatbed scanner right cover removal
Flatbed scanner rear cover removal
Flatbed scanner top cover removal
Flatbed scanner support removal
Flatbed scanner frame latch removal
Flatbed scanner CCDM removal
Flatbed scanner board removal
Flatbed scanner gear removal
Motor (flatbed scanner) removal
Sensor (flatbed scanner home position)
Flatbed scanner tensioner pulley removal
550-sheet tray removals
550-sheet tray media size sensor actuators removal
Sensor (550-sheet tray media size) removal
Sensor (550-sheet tray media low) removal
Sensor (550-sheet tray jam door)
550-sheet tray right rail removal
550-sheet tray paper feeder removal
Sensor (550-sheet tray media out) removal
550-sheet tray rear cover removal
550-sheet tray controller board removal
550-sheet tray interface cable removal
Sensor (550-sheet tray pick roller index) removal
550-sheet tray left rail removal
Motor (550-sheet tray pass-through) removal
550-sheet tray wake up switch removal
2200-sheet tray removals
2200-sheet tray insert removal
Bell crank removal
2200-sheet tray rail removal
Sensor (2200-sheet tray media low) removal
Sensor (2200-sheet tray media size) removal
2200-sheet tray rear cover removal
2200-sheet tray controller board removal
2200-sheet tray interface cable removal
2200-sheet tray elevator gears removal
Motor (2200-sheet tray elevator) removal
2200-sheet tray paper feeder removal
Sensor (2200-sheet tray media out) removal
Sensor (2200-sheet tray pick roller index) removal
Motor (2200-sheet tray pick) removal
2200-sheet tray media out sensor actuator removal
2200-sheet tray wake up switch removal
Caster base removals
Locking caster removal
Non-locking caster removal
Staple finisher removals
Staple finisher right cover removal
Staple finisher front cover removal
Staple finisher rear cover removal
Staple finisher controller board removal
Staple finisher staple cartridge door removal
Staple finisher jam access door removal
Staple finisher lock assembly removal
Staple finisher bottom cover removal
Staple finisher staple cartridge door switch removal
Staple finisher inner rear cover removal
Sensor (staple finisher lower bin full) removal
Sensor (staple finisher upper bin full) removal
Motor (staple finisher upper exit roller) removal
Staple finisher rear upper position exit roller gears removal
Staple finisher staple unit ejector removal
Sensor (staple finisher stack clamp) removal
Staple finisher staple unit removal
Staple finisher jam door switches removal
Staple finisher stack clamp removal
Staple finisher stack clamp solenoid removal
Motor (staple finisher aligner paddle) removal
Staple finisher transport gears removal
Staple finisher aligner paddle gears removal
Sensor (staple finisher upper exit roller) removal
Staple finisher exit gears removal
Staple finisher front upper position exit roller gears removal
Staple finisher exit roller belts removal
Staple finisher tamper assembly removal
Staple finisher tamper top cover removal
Sensor (staple finisher tamper position) removal
Motor (staple finisher tamper) removal
Staple finisher tamper belts removal
Staple finisher tamper pulley gear removal
Staple finisher tamper removal
Staple finisher bin link removal
Staple finisher bin removal
Staple finisher compiler feed roller removal
Staple finisher compiler paper guide removal
Staple finisher compiler feed idler removal
Staple finisher aligner paddle and upper paper guide removal
Staple finisher upper exit roller removal
Staple finisher entrance paper guide removal
Staple finisher bin clamp assembly removal
Sensor (staple finisher bin clamp) removal
Motor (staple finisher bin clamp) removal
Motor (staple finisher exit) removal
Motor (staple finisher transport) removal
Sensor (staple finisher staple unit paper present) removal
Sensor (staple finisher transport) removal
Horizontal paper transport removals
HPT front cover removal
HPT front inner cover removal
Sensor (HPT jam cover) removal
HPT front transport belt removal
HPT front transport belt gear removal
HPT rear cover removal
HPT fan removal
HPT controller board removal
HPT transport belts removal
Hole punch unit cover removal
Hole punch unit removal
Motor (hole punch unit) removal
Hole punch unit gears removal
Sensor (hole punch unit) removal
HPT transport assembly removal
Motor (HPT transport) removal
HPT transport gears removal
HPT transport drive belt removal
HPT top cover removal
HPT transport idler roller removal
HPT top door removal
HPT lock removal
HPT autoconnect cable removal
Sensor (HPT transport) removal
Sensor (HPU entrance) removal
HPT alignment rollers removal
HPT transport rollers removal
Multiposition staple, hole punch finisher removals
MSHPF power supply cover removal
MSHPF bottom left cover removal
MSHPF front door removal
Knobs J2 and J7 removal
MSHPF door hinge removal
MSHPF front left cover removal
MSHPF inner front cover removal
MSHPF staple cartridge door removal
MSHPF left front cover removal
MSHPF right cover removal
MSHPF bottom right cover removal
Stapler bin cave cover removal
MSHPF bin light board removal
MSHPF right frame cover removal
MSHPF controller board cover removal
MSHPF rear cover removal
MSHPF power supply removal
MSHPF inner top cover removal
MSHPF top frame covers removal
MSHPF controller board removal
Switch (MSHPF cartridge door interlock) removal
Sensor (cartridge loading position) removal
Sensor (stapler bin lower limit) removal
MSHPF staple unit carriage removal
Sensor (MSHPF staple unit position) removal
Sensor (MSHPF staple unit paper present) removal
MSHPF staple unit removal
Staple unit extension cable removal
Sensor (MSHPF door interlock) removal
Sensor (stapler bin stack upper limit) removal
Compiler entrance belt tensioner removal
Hole punch box belt removal
Hole punch box pulley gear removal
Staging outer transport belt removal
Staging outer transport pulley gear removal
Motor (staging diverter) removal
Sensor (staging diverter) removal
Sensor (hole punch box present) removal
Motor (staging outer transport) removal
Motor (staging inner transport) removal
Staging transport gears removal
Staging transport belts removal
Offset belt tensioner removal
MSHPF standard bin exit belt removal
Mid-transport pulley gears removal
Motor (mid-transport) removal
Mid-transport gear removal
Mid-transport interface board removal
Mid-transport (HPT) interface cable removal
Mid-transport (mailbox) interface cable removal
Sensor (standard bin stack upper limit) removal
Standard bin elevator drive removal
Motor (standard bin elevator) removal
Sensor (standard bin paper present) removal
Sensor (offset roller) removal
MSHPF top frame removal
Offset assembly removal
Motor (mid-transport diverter) removal
Sensor (mid-transport diverter 1) removal
Mid-transport diverter cams and gear removal
Sensor (hole punch box full, receiver) removal
Sensor (hole punch box full, transmitter) removal
Mid-transport mailbox entrance frame removal
Mid-transport diverter 1 removal
Mid-transport guide removal
Door J1 removal
Mid-transport diverter 2 removal
Sensor (MSHPF standard bin exit) removal
Sensor (door N interlock) removal
Sensor (mid-transport) removal
Sensor (staging outer transport 1) removal
Sensor (staging entrance) removal
Mid-transport and staging assembly removals
Mid-transport and staging assembly removal
MSHPF standard bin assembly removal
Staging paper guide removal
Staging inner transport roller removal
Staging diverter removal
Staging exit guide removal
Multiposition stapler assembly removals
Multiposition stapler assembly removal
Motor (MSHPF front tamper) removal
Motor (MSHPF rear tamper) removal
MSHPF tamper belt removal
MSHPF tamper pulley gear removal
Sensor (MSHPF tamper) removal
MSHPF tampers removal
Compiler interface board removal
Motor (compiler stack height) removal
Sensor (compiler stack height) removal
Stack height assembly removal
Sensor (compiler exit cam) removal
Sensor (compiler paddle) removal
Motor (compiler exit cam) removal
Compiler paddle and exit drive removal
Compiler exit roller removal
Motor (compiler paddle) removal
Stapler bin lower exit roller belt removal
Stapler bin lower exit roller pulley gear removal
Compiler entrance guide removal
Compiler entrance upper roller removal
Compiler gears removal
MSHPF compiler tray removal
Sensor (compiler paper present) removal
Motor (MSHPF bin clamp) removal
Sensor (MSHPF bin clamp home) removal
Stapler bin lower exit roller removal
Motor (stapler bin elevator) removal
Stapler bin elevator drive removal
Staple unit carriage belt removal
Motor (staple unit carriage) removal
Staple unit cable removal
Stapler bin assembly removal
Stapler bin assembly cables removal
Sensor (staging inner transport 1) removal
Sensor (staging inner transport 2) removal
Cabinet removals
Cabinet door removal
Cabinet door hinge removal
Cabinet removal
Cabinet right wheel removal
Cabinet left wheel removal
Cabinet brackets removal
Cabinet upper covers removal
Cabinet lower covers removal
Finisher lock button removal
Finisher lock latch removal
2-bin mailbox removals
Mailbox bail removal
Mailbox jam door removal
Mailbox front cover removal
Motor (mailbox diverter) removal
Mailbox rear cover removal
Mailbox controller board removal
Motor (mailbox transport) removal
Sensor (mailbox jam door) removal
Mailbox interface cable removal
Mailbox latch removal
Mailbox bottom cover removal
Mailbox top cover removal
Mailbox front inner cover removal
Sensor (mailbox diverter home) removal
Mailbox diverter removal
Mailbox diverter gear removal
Mailbox rear inner cover removal
Sensor (mailbox bin 1 full) removal
Sensor (mailbox bin 2 full) removal
Mailbox drive belt removal
Mailbox bin 2 full sensor flag removal
Mailbox bin 1 full sensor flag removal
Sensor (mailbox bin 2 paper present) removal
Sensor (mailbox bin 1 paper present) removal
Bin light board removal
Sensor (mailbox transport) removal
Mailbox bin 2 pulley gear removal
Mailbox bin 1 pulley gear removal
Mailbox drive gears removal

Printer configurations
Printer roller locations
Printer sensor locations
Printer motor locations
Power supply locations-Rear
ADF roller locations
ADF sensor locations
Staple finisher locations
HPT locations
MSHPF sensor locations
MSHPF motor locations
Mailbox locations

Scheduled maintenance
Maintenance kits
Resetting the maintenance counter
Cleaning printer parts
Cleaning the printer
Cleaning the scanner glass
Emptying the hole punch box

Assembly 1: Covers 1
Assembly 2: Covers 2
Assembly 3: Covers 3
Assembly 4: Control panel
Assembly 5: Duplex
Assembly 6: Left door
Assembly 7: Feeder
Assembly 8: Frame
Assembly 9: Fuser
Assembly 10: Electronics-Front
Assembly 11: Electronics-Rear
Assembly 12: Registration
Assembly 13: Motors
Assembly 14: Printhead
Assembly 15: Toner supply
Assembly 16: Redrive
Assembly 17: Transfer-Front
Assembly 18: Transfer-Rear
Assembly 19: ADF 1
Assembly 20: ADF 2
Assembly 21: ADF 3
Assembly 22: ADF 4
Assembly 23: ADF 5
Assembly 24: ADF 6
Assembly 25: Flatbed scanner 1
Assembly 26: Flatbed scanner 2
Assembly 27: Flatbed scanner 3
Assembly 28: 550-sheet tray
Assembly 29: 550-sheet tray-Rear
Assembly 30: 550-sheet tray-Front
Assembly 31: 2200-sheet tray
Assembly 32: 2200-sheet tray-Front
Assembly 33: 2200-sheet tray-Rear
Assembly 34: Caster base
Assembly 35: Cables
Assembly 36: Maintenance kits
Assembly 37: Power cords
Assembly 38: Miscellaneous
Assembly 39: Staple finisher option
Assembly 40: Staple finisher-Covers
Assembly 41: Staple finisher-Front
Assembly 42: Staple finisher-Electrical
Assembly 43: Staple finisher-Rear
Assembly 44: Staple finisher-Tamper
Assembly 45: Staple finisher-Transport
Assembly 46: Staple finisher-Bottom
Assembly 47: Mailbox 1
Assembly 48: Mailbox 2
Assembly 49: Mailbox 3
Assembly 50: Mailbox 4
Assembly 51: Mailbox 5
Assembly 52: HPT 1
Assembly 53: HPT 2
Assembly 54: HPT 3
Assembly 55: HPT 4
Assembly 56: HPT 5
Assembly 57: MSHPF covers 1
Assembly 58: MSHPF covers 2
Assembly 59: MSHPF electronics
Assembly 60: MSHPF mid-transport drive
Assembly 61: MSHPF mid-transport paper path
Assembly 62: MSHPF offset drive
Assembly 63: MSHPF standard bin 1
Assembly 64: MSHPF standard bin 2
Assembly 65: MSHPF transport roller and hole punch box
Assembly 66: MSHPF staging drive
Assembly 67: MSHPF staging paper path
Assembly 68: MSHPF compiler 1
Assembly 69: MSHPF compiler 2
Assembly 70: MSHPF tamper
Assembly 71: MSHPF carriage transport
Assembly 72: MSHPF door interlock
Assembly 73: MSHPF stapler bin 1
Assembly 74: MSHPF stapler bin 2
Assembly 75: MSHPF stapler bin 3
Assembly 76: MSHPF cabinet
Assembly 77: Miscellaneous, MSHPF

Power consumption
Product power consumption
Sleep Mode
Hibernate Mode
Off mode
Total energy usage
Selecting a location for the printer
Noise emission levels
Temperature information

Available internal options
Input/output configurations and capacities
Input capacity by paper and source
Output capacity by paper and source
Physical specifications (input options)
Output options supported

POR sequence
Print cycle operation
Print engine layout
Print cycle
Fresh toner delivery drive
Developer drive
Photoconductor drive
Black only retract (BOR) drive
Waste toner delivery drive
Printhead lens cleaner drive
Printer operation
Printer sections
Printer paper path
Printer paper path sensors
MPF pick drive
Tray 1 lift and pick drive
MPF/pass-through and isolation drive
Registration drive
Transfer belt drive
Fuser drive
Exit and redrive drive
Diverter drive
Duplex path drive
ADF and scanner operation
Flatbed scanner drive
ADF paper path
ADF paper path sensors
ADF double-feed detection
ADF tray lift drive
ADF tray pick and feed drive
ADF separator drive
ADF registration drive
ADF scan and exit drive
ADF calibration drive
2200-sheet tray operation
Paper presence and size detection
Paper lift and feed
Staple finisher operation
Staple finisher sections
Staple finisher feed section
Compiler section feed and paper alignment
Offset and stapling operation
Compiler section exit
Bin section
Multiposition staple, hole punch finisher operation
Finisher sections
HPT paper path
HPT drive
HPU drive
Finisher standard bin paper path
Finisher standard bin paper path sensors
Mid-transport diverter drive
Finisher standard bin transport drive
Finisher standard bin offset drive
Finisher standard bin elevator drive
Finisher stapler bin paper path
Finisher stapler bin paper path sensors
Finisher staging diverter drive
Finisher staging transport drive
Compiler tray edge alignment drive
Compiler tray stack height detection
Finisher staple unit carriage drive
Finisher stapler bin exit drive
Finisher stapler bin clamp drive and upper limit detection
Finisher stapler bin elevator drive
2-bin mailbox operation

Appendix D: ACRONYMS
Part number index
Part name index

Number of pages: 1568.
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