LEXMARK CS720, CS725, CX725 & C4150, XC4150

LEXMARK CS820, CX820, CX825, CX860 & C6160, XC6152, XC8155, XC8160

LESSON 1: REPAIR AND TROUBLESHOOTING

INTRODUCTION We will learn how to remove, install, adjust, calibrate (if applicable), troubleshoot, and repair
major components in the printer and options.

IMPORTANCE You will frequently replace major components during repair actions. You want to find the
component quickly and do a proper removal and installation – if not, you could create more
problems or failures. You should be aware that some components require special adjustments
or calibrations in order to function within recommended guidelines. These special procedures
are important; failure to complete them may cause you a repeat service call.

LESSON OVERVIEW This lesson will teach you the location of the major components, the procedure to
remove/install them, and any special procedures needed before/during/after the repair
action. In addition, you will practice applying your knowledge of the electrophotographic
process and paper path and transport systems by troubleshooting problem scenarios using
available support tools.

OBJECTIVES You will

• locate each component in the provided removal table
• remove (or point to if indicated) each component correctly
• reinstall the component correctly
• perform any adjustments or calibrations before/during/after the repair
• apply your knowledge of the electrophotographic process and paper path and
transport systems by troubleshooting problem scenarios
• use all available support tools (Service Manual, Knowledgebase, Study Guide, etc.)

ORDER OF TOPICS Topic Go to page

Lexmark CS720, CS725, CX725 & C4150, XC4150 Product Overview 2

Lexmark CS820, CX820, CX825, CX860 & C6160, XC6152, XC8155, XC8160
3
Product Overview

Review: Service Manual Contents 4

Review: Job Aids and Support Tools 5

Lexmark CS820, CX820, CX825, CX860 & C6160, XC6152, XC8155, XC8160
8
Toner Contact Demonstration

Practice: Lexmark CS820, CX820, CX825, CX860 & C6160, XC6152, XC8155,
9
XC8160 Component Removal/Installation and Adjustments

Practice: Lexmark CS820, CX820, CX825, CX860 & C6160, XC6152, XC8155,
12
XC8160 Troubleshooting and Repair Scenarios

Practice: Lexmark CS720, CS725, CX725 & C4150, XC4150 Component

19
Removal/Installation and Adjustments

Practice: Lexmark CS720, CS725, CX725 & C4150, XC4150 Troubleshooting and
21
Repair Scenarios

Lesson Summary 28

Lexmark Classroom Learning 1 V1.2

 LEXMARK CS720, CS725, CX725 & C4150, XC4150 PRODUCT OVERVIEW

The instructor(s) will show you a short presentation on the Lexmark CS720, CS725, CX725 & C4150, XC4150
product line. Use the blank space below to write down key information or questions you may have. As a guide,
we’ve included some things to think about:

How does this printer differ from previous products?

How is his product similar to previous products?

What are three things that you think are most useful?

What are things you want to explore further or have questions about?

Lexmark Classroom Learning 2 V1.2

LEXMARK CS820, CX820, CX825, CX860 & C6160, XC6152, XC8155, XC8160 PRODUCT
OVERVIEW

The instructor(s) will show you a short presentation on the Lexmark CS820, CX820, CX825, CX860 & C6160,
XC6152, XC8155, XC8160 product line. Use the blank space below to write down key information or questions
you may have. As a guide, we’ve included some things to think about:

How does this printer differ from previous products?

How is his product similar to previous products?

What are three things that you think are most useful?

What are things you want to explore further or have questions about?

Lexmark Classroom Learning 3 V1.2

 SERVICE MANUAL CONTENTS

The Service Manual is an indispensable tool to help you troubleshoot, diagnose,

replace parts, and repair the equipment. Since the manual tends to be quite large,
we’ll look at several key sections you’ll want to focus on in your job.

DIAGNOSTIC INFORMATION

• Contains general and in-depth troubleshooting guidelines for print

quality, scan quality, paper jams, attendance messages, and error codes.
• This would be a good place to begin when troubleshooting.

SERVICE MENUS

• Contains general information on the Control Panel buttons and Icons.

• Contains a menu tree of the Customer Menus.
• Contains information on accessing special menus such as Diagnostics
Menu.
• Contains detailed Service Menu listings useful in repair and
troubleshooting.

REPAIR INFORMATION
Critical Helpful
• Contains detailed information on removal precautions, special Content Content
procedures, and adjustments. You should glance through this section
before replacing any parts to see if any of it applies to you.
• Contains the removal procedures for the print components. Before
removing a part, read through the entire procedure – sometimes there
are cautions or warnings that you will need to keep in mind.

COMPONENT LOCATIONS

• Shows the locations of major parts and components in the printer.

• Although this section isn’t critical, it may come in handy to show you where parts are located within the
equipment.

M AINTENANCE

• Lists the contents for the maintenance kits and its part number.
• Shows you how to reset the maintenance counter for manual items and lists the items that automatically
reset.
• Contains information general housekeeping for preventative maintenance such as cleaning parts,
emptying the hole punch box, etc.

THEORY OF OPERATION

• Contains detailed illustrations and theory about the operation of the printer and options.
• Although this section isn’t critical to repair, this section is critical to understanding how the printer
operates, which will help you troubleshoot a problem. If you are unfamiliar with the printer, or, haven’t
seen one in a while, review this section.

Lexmark Classroom Learning 4 V1.2

 JOB AIDS AND SUPPORT TOOLS

You have several job aids and support tools at your disposal to help with a repair call. The Service Manual is the
ultimate job aid, but others exist as well. These include:

• Knowledgebase Articles
• Study Guide
• Technical Service Bulletins

These helpful resources are all found on the Lexmark support site called Knowledgebase (support.lexmark.com).
It is full of the latest and greatest information including Support articles, Technical Service Bulletins, Service
Manuals, Study Guides, etc. Here is how you access it:

• Go to support.lexmark.com and log in. Next, type in the model

name of the printer and click Go.

You must log in to access technician level articles and

information.

• From here, select your model to go to its product landing page.

This would be a good place to begin before going on a repair

call or starting any troubleshooting.

• Now that you’re at the product landing page, let’s

look at some of the helpful areas in detail.

Lexmark Classroom Learning 5 V1.2

TOP ARTICLES TAB

• Select the tab for Top Articles to view

the latest Knowledgebase support
articles for your selected product.
• If you know what you want to look for,
type in a keyword search and click
Search.

You need to access this section in

this course for the Troubleshooting and
Repair Scenarios.

SERVICE BULLETINS TAB

• Select the tab for Service Bulletins to

view hot tips and fixes that may not be
in the Service Manual.

This would be a good place to

browse before going on a repair call for
a product.

SERVICE MANUALS TAB

• Select the tab for Service Manuals to

view the latest Service Manuals for the
product as well as the Lexmark Mobile
Tech tool.
• The Study Guide may be moved to this
location is the future. It contains
condensed product information and
expanded technical information beyond
the Service Manual.

Lexmark Classroom Learning 6 V1.2

MANUALS TAB

• Select the tab for Manuals to view the

latest User’s Guides, Fax Guides, and
other customer-level documents.
• Currently, the Study Guide is located in
this tab. It is under the Technical Guides
heading, but can only be seen if you are
logged in.

This guide is an excellent resource

aid and will come in handy for the
several sections of this course.

DOWNLOADS TAB

• Select the tab for Downloads to view the

current drivers and firmware for the
product (as well as previous revisions).

It is always a good idea to grab a

copy of the latest firmware for a product
before going to do repair – just in case you
need it.

HOW-TO VIDEOS TAB

• Select the tab for How-To Videos to view

videos on how to perform basic tasks on
the product. As this time, these videos are
customer level but you may find it useful as
a reminder of how-to-do certain tasks if it’s
been a while since you’ve seen the
product.

Lexmark Classroom Learning 7 V1.2

 LEXMARK CS820, CX820, CX825, CX860 & C6160, XC6152, XC8155, XC8160 TONER
CONTACT DEMONSTRATION

DEMONSTRATION

One of the more difficult repairs you may need to perform on this product involves the Toner Contact. The Study
Guide lists this as one of several “Complex Parts” due to its location in the machine and skill needed to repair.
Please review the information in the Study Guide prior to the demonstration.

Your instructor(s) will demonstrate how to remove and install this part on a machine that is already torn apart.
Once the demonstration is complete, you will be able to practice on your own. While watching the
demonstration, write any notes or questions you may have below:

What are some of the more difficult parts of this repair?

What are things that may cause me problems in this repair?

What are things that I can do to make it easier during the repair?

Lexmark Classroom Learning 8 V1.2

 LEXMARK CS820, CX820, CX825, CX860 & C6160, XC6152, XC8155, XC8160
COMPONENT REMOVAL/INSTALLATION AND ADJUSTMENTS

PRODUCT TEARDOWN

The table below lists the components you need to remove and install. Parts marked with a have a special
procedure that should be performed such as a calibration, adjustment, or other special handling. Once you
complete the teardown of the machine, perform the special procedure(s) needed for each marked part.

Refer to the Study Guide for more information on the complex parts before you begin disassembly. Use the
Service Manual removal procedures to remove/install each part and perform any necessary special procedures.

Part Difficulty Type / Notes

Printer

Toner Cartridges

Waste Toner Bottle

Transfer Module

Fuser

2nd Transfer Roller

Developer Unit

Photoconductor Unit

Pick Roller

• Special Procedure(s)/Calibration(s) Needed

Control Panel
• Damage / Error Risk

Separator Bracket

• High Technical Repair Skill

Controller Board • Special Procedure(s)/Calibration(s) Needed
• Damage / Error Risk

• High Technical Repair Skill

Secure Element SIM Card • Special Procedure(s)/Calibration(s) Needed
(if present)
• Damage / Error Risk

Lexmark Classroom Learning 9 V1.2

 • Special Procedure(s)/Calibration(s) Needed
Laser (Printhead) • Special Tool(s) Needed

Main HVPS

Charge Roller HVPS

Main Fan

LVPS • Damage / Error Risk

• Damage / Error Risk

EP, Developer, Toner Add Gearbox (EP
• Other <Contains a memory chip with PC Drive calibration settings>
Drive)
• Other <Big and burdensome part>

Fuser / Transfer Module Gearbox • Special Procedure(s)/Calibration(s) Needed

• High Technical Repair Skill

Left Door Assembly
• Other <Difficult installation>

• Damage / Error Risk

Smartchip Interface Board
• Other <Difficult access>

• High Technical Repair Skill

Toner Contacts <DO NOT REMOVE> • Damage / Error Risk
• Other <Difficult access>

• High Technical Repair Skill

Transfer Module Contact
• Other <Difficult access>

Scanner

ADF Pick Roller

ADF Separator Roller

ADF feed belt

Flatbed Scanner CCDM

Flatbed Scanner Board

Horizontal Paper Transport (HPT)

HPT Controller Board

Lexmark Classroom Learning 10 V1.2

 Hole Punch Unit

Professional Finisher (Multiposition staple, hole punch finisher (MSHPF))

MSHPF Power Supply

MSHPF Controller Board

MSHPF Staple Unit

Lexmark Classroom Learning 11 V1.2

 LEXMARK CS820, CX820, CX825, CX860 & C6160, XC6152, XC8155, XC8160
TROUBLESHOOTING AND REPAIR SCENARIOS

SCENARIOS

These scenarios allow you to practice your troubleshooting and repair skills on the printer. Use the
Knowledgebase (support.lexmark.com), Service Manual, Study Guide, or any other resources to solve each
problem.

Always check the Knowledgebase first for articles or technical bulletins – these may contain information
not found in the Service Manual.

PROBLEM 1 You are dispatched to examine a CS820 printer posting magenta toner empty messages when
the magenta toner is actually full. The customer replaced the toner three times already.
Within a short period of time, however, the printer says the magenta is empty.

Using available resources 1) find the potential cause(s) of the problem and 2) determine what
needs to be done to fix it. Then, write down what you would do to find the cause(s) and then
what you would do to fix it.

SOLUTION

Lexmark Classroom Learning 12 V1.2

PROBLEM 2 You are onsite to troubleshoot a print quality
problem on a CX825 fully loaded printer. After
running the advanced print quality pages, you see the
vertical light streaks in the black halftone pages that
look similar to this sample:

Using available resources 1) find the potential

cause(s) of the problem and 2) determine what needs
to be done to fix it. Then, write down what you
would do to find the cause(s) and then what you
would do to fix it.

SOLUTION

Lexmark Classroom Learning 13 V1.2

PROBLEM 3 You are dispatched to look at a CS820 printer with a 156.80 service error.

Using available resources 1) find the potential cause(s) of the problem and 2) determine what
needs to be done to fix it. Then, write down what you would do to find the cause(s) and then
what you would do to fix it.

SOLUTION

Lexmark Classroom Learning 14 V1.2

PROBLEM 4 You go onsite to look at a CX825 fully loaded printer. The customer says they are getting
457.25 errors.

Using available resources 1) find the potential cause(s) of the problem and 2) determine what
needs to be done to fix it. Then, write down what you would do to find the cause(s) and then
what you would do to fix it.

SOLUTION

Lexmark Classroom Learning 15 V1.2

PROBLEM 5 You go on site to look at a CX825 fully loaded printer. The customer says they are getting
450.25 and 450.21 errors. On inspection, you don’t find any paper in the paper path.

Using available resources 1) find the potential cause(s) of the problem and 2) determine what
needs to be done to fix it. Then, write down what you would do to find the cause(s) and then
what you would do to fix it.

SOLUTION

Lexmark Classroom Learning 16 V1.2

PROBLEM 6 Team up with another person (or two) – or with an instructor to do the following:

Explain the Electrophotographic process to the other team member(s) or instructor. Point out
specific components and explain their function/role in the process. Name at least one print
quality problem that could be caused by each part.

SOLUTION

Lexmark Classroom Learning 17 V1.2

PROBLEM 7 Team up with another person (or two) – or with an instructor to do the following:

Explain the Paper Path and Transport System (for the Scanner/Printer/Finisher) to the other
team member(s) or instructor. Point out specific components and explain their function/role
in the process. Name at least one paper-related problem that could be caused by each part.

SOLUTION

Lexmark Classroom Learning 18 V1.2

LEXMARK CS720, CS725, CX725 & C4150LEXMARK CS720, CS725, CX725 & C4150,
XC4150 COMPONENT REMOVAL/INSTALLATION AND ADJUSTMENTS

PRODUCT TEARDOWN

The table below lists the components you need to remove and install. Parts marked with a have a special
procedure that should be performed such as a calibration, adjustment, or other special handling. Once you
complete the teardown of the machine, perform the special procedure(s) needed for each marked part.

Refer to the Study Guide for more information on the complex parts before you begin disassembly. Use the
Service Manual removal procedures to remove/install each part and perform any necessary special procedures.

Part Difficulty Type / Notes

Printer

Toner Cartridges

Waste Toner Bottle

Imaging Basket • Damage / Error Risk

Fuser

Transfer Module • Special Procedure(s)/Calibration(s) Needed

• Special Procedure(s)/Calibration(s) Needed

Control Panel • Damage / Error Risk

• High Technical Repair Skill

Secure Element SIM Card • Special Procedure(s)/Calibration(s) Needed
(if present)
• Damage / Error Risk

• High Technical Repair Skill

Controller Board • Special Procedure(s)/Calibration(s) Needed
• Damage / Error Risk

Laser (Printhead) • Special Procedure(s)/Calibration(s) Needed

Media Feeder

LVPS

HVPS • Other <Print Quality issue>

Lexmark Classroom Learning 19 V1.2

 Scanner

ADF Pick Roll

ADF Separator Roll

ADF Removal • Special Procedure(s)/Calibration(s) Needed

ADF Top Cover

ADF Left Hinge

ADF Right Hinge

Scanner Front Cover

Left Flatbed Cover

Flatbed Removal • Special Procedure(s)/Calibration(s) Needed

Lexmark Classroom Learning 20 V1.2

 LEXMARK CS720, CS725, CX725 & C4150, XC4150 TROUBLESHOOTING AND REPAIR
SCENARIOS

SCENARIOS

These scenarios allow you to practice your troubleshooting and repair skills on the printer. Use the
Knowledgebase (support.lexmark.com), Service Manual, Study Guide, or any other resources to solve each
problem.

Always check the Knowledgebase first for articles or technical bulletins – these may contain information
not found in the Service Manual.

PROBLEM 1 You are dispatched to install a CS725 printer at a remote location. After installing it along with
the options, on first power on it posts a 161.80 Error. You POR the machine, but the error
remains.

Using available resources 1) find the potential cause(s) of the problem and 2) determine what
needs to be done to fix it. Then, write down what you would do to find the cause(s) and then
what you would do to fix it.

SOLUTION

Lexmark Classroom Learning 21 V1.2

PROBLEM 2 You receive a call to update the firmware on a CX725 printer. You download the latest code
and put it on your USB Drive. Once you arrive onsite, you plug in your thumb drive in the
front USB port, but the USB seems to freeze. You get no response.

Using available resources 1) find the potential cause(s) of the problem and 2) determine what
needs to be done to fix it. Then, write down what you would do to find the cause(s) and then
what you would do to fix it.

SOLUTION

Lexmark Classroom Learning 22 V1.2

PROBLEM 3 A customer complains that their CS720 is posting 200.13 messages frequently.

Using available resources 1) find the potential cause(s) of the problem and 2) determine what
needs to be done to fix it. Then, write down what you would do to find the cause(s) and then
what you would do to fix it.

SOLUTION

Lexmark Classroom Learning 23 V1.2

PROBLEM 4 You are dispatched to investigate a customer complaint that the printer is “dirty”. When you
arrive onsite, the inside of the printer is contaminated with toner dust.

Using available resources 1) find the potential cause(s) of the problem and 2) determine what
needs to be done to fix it. Then, write down what you would do to find the cause(s) and then
what you would do to fix it.

SOLUTION

Lexmark Classroom Learning 24 V1.2

PROBLEM 5 You are sent to check a CX725 printer reporting 281.16 errors. The problem started after the
customer removed a paper jam.

Using available resources 1) find the potential cause(s) of the problem and 2) determine what
needs to be done to fix it. Then, write down what you would do to find the cause(s) and then
what you would do to fix it.

SOLUTION

Lexmark Classroom Learning 25 V1.2

PROBLEM 6 Team up with another person (or two) – or with an instructor to do the following:

Explain the Electrophotographic process to the other team member(s) or instructor. Point out
specific components and explain their function/role in the process. Name at least one print
quality problem that could be caused by each part.

SOLUTION

Lexmark Classroom Learning 26 V1.2

PROBLEM 7 Team up with another person (or two) – or with an instructor to do the following:

Explain the Paper Path and Transport System (for the Scanner/Printer/Finisher) to the other
team member(s) or instructor. Point out specific components and explain their function/role
in the process. Name at least one paper-related problem that could be caused by each part.

SOLUTION

Lexmark Classroom Learning 27 V1.2

 LESSON SUMMARY

WHAT YOU In this course, you learned how to

LEARNED
• locate components in the printer
• remove components correctly
• reinstall components correctly
• perform adjustments or calibrations before/during/after the repair
• use your knowledge of the electrophotographic process and paper path and
transport systems to troubleshoot problems
• use resource tools such as the Service Manual, Knowledgebase, Study Guide, etc. to
perform repairs, adjustments/calibrations and troubleshoot problems

PRINTER Lexmark CS720, CS725, CX725 & C4150, XC4150

HIGHLIGHTS
• New architecture – replacing the C746/X746 and C748/X748
• Looks and feels a lot like the CX51x printers
• May have a Secure Element SIM Card on the Controller Board (it is optional) – the
SIM has to be moved over to the new Controller Board if replaced!
• Has new BOR for black only printing to disengage the colors
• Has both mechanical and electronic deskew in scanner
• New “gap” calibration – faster and reduces toner usage
• New Android Control Panel GUI
• Diagnostic Menu and Configuration Menu accessed directly from a “Ready” state
• Redesigned EWS

Lexmark CS820, CX820, CX825, CX860 & C6160, XC6152, XC8155, XC8160
• New architecture – replacing the C792/X792
• Has BOR for black only printing to disengage the colors
• May have a Secure Element SIM Card on the Controller Board (optional on all models
but STANDARD on the CX860) – the SIM has to be moved over to the new Controller
Board if replaced!
• Has a two-piece supplies system (Photoconductor + Developer = Imaging Unit
(Combo Unit))
• Toner Cartridge only holds toner
• Laser located underneath Imaging units – lenses may need to be cleaned (removing
Waste Toner Bottle will initiate a small clean, a bigger clean located in Diagnostics at
Printer setup > EP setup > Toner patch sensor adjust > Clean sensing and laser optics.
A dirty lens will be the most likely suspect for Vertical Streaking.
• Toner Contacts and Drop Tubes buried in back of machine – difficult repair
• Left side door installation is very difficult to install unless you follow the installation
instructions carefully
• New Staple Finisher (all models) and Professional Finisher (Multiposition staple, hole
punch finisher (MSHPF)) option (860 models only)
• Has a proximity detector to wake up the printer when someone approaches (CX825
and CX860 only)
• New Android Control Panel GUI
• Diagnostic Menu and Configuration Menu accessed directly from a “Ready” state
• Redesigned EWS

Lexmark Classroom Learning 28 V1.2