Utax P-C2660DN User manual

Service
Manual
Color Printer
P-C2160DN
P-C2660DN
Rev.: 3.0
Date: 28-03-2014
2PTSM063

CAUTION
RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE. DISPOSE
OF USED BATTERIES ACCORDING TO THE INSTRUCTIONS.
It may be illegal to dispose of this battery into the municipal waste stream. Check with your
local solid waste officials for details in your area for proper disposal.
ATTENTION
IL Y A UN RISQUE D’EXPLOSION SI LA BATTERIE EST REMPLACEE PAR UN MODELE
DE TYPE INCORRECT. METTRE AU REBUT LES BATTERIES UTILISEES SELON LES
INSTRUCTIONS DONNEES.
Il peut être illégal de jeter les batteries dans des eaux d’égout municipales. Vérifiez avec les
fonctionnaires municipaux de votre région pour les détails concernant des déchets solides
et une mise au rebut appropriée.
For the purpose of this service manual, products are identified by print speed at A4.
P-C2160DN : 21 ppm model
P-C2660DN : 26 ppm model

Revision history
Revision Date Pages Revised contents
1 20 January 2014 Contents Added: 2-4-1 (4) and page numbers of contents
1-3-8 Added: Supplement of the (59)/(60)/(61)
1-5-28, 29 Correction: Number of screw. (3→4)
2-4-9 Added: (4)Maintenance Commands
2-4-10 Correction: (4) →(5)
Address Correction
2 17 February 2014 1-1-2 Correction: Power source →Rated input
1-2-1 Correction: 8.5 A →9.0 A, 4.5 A →5.0 A
1-3-7 Added: into the description of (49) Media type attributes
1-6-1 Correction: The statement of a safe mode
1-6-2 Correction: SD CARD →USB memory
2-4-1 Added: Exchange time of MK
2-4-2 Added: Comment to (2)Repetitive defects gauge
2-4-9 Added: The comment about three steps is written in the
preset value column.
3 18 March 2014 1-1-1,1-1-2 Correction: Sleep mode, USB host

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Safety precautions
This booklet provides safety warnings and precautions for our service personnel to ensure the safety of
their customers, their machines as well as themselves during maintenance activities. Service personnel
are advised to read this booklet carefully to familiarize themselves with the warnings and precautions
described here before engaging in maintenance activities.

Safety warnings and precautions
Various symbols are used to protect our service personnel and customers from physical danger and
to prevent damage to their property. These symbols are described below:
DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect
compliance with warning messages using this symbol.
WARNING: Serious bodily injury or death may result from insufficient attention to or incorrect compliance
with warning messages using this symbol.
CAUTION: Bodily injury or damage to property may result from insufficient attention to or incorrect com-
pliance with warning messages using this symbol.
Symbols
The triangle ( ) symbol indicates a warning including danger and caution. The specific point of attention is
shown inside the symbol.
General warning. Warning of risk of electric shock.
Warning of high temperature.
indicates a prohibited action. The specific prohibition is shown inside the symbol.
General prohibited action. Disassembly prohibited.
indicates that action is required. The specific action required is shown inside the symbol.
General action required. Remove the power plug from the wall outlet.
Always ground the copier.

1. Installation Precautions
WARNING
• Do not use a power supply with a voltage other than that specified. Avoid multiple connections to
one outlet: they may cause fire or electric shock. When using an extension cable, always check that
it is adequate for the rated current. .....................................................................................................
• Connect the ground wire to a suitable grounding point. Not grounding the copier may cause fire or
electric shock. Connecting the earth wire to an object not approved for the purpose may cause
explosion or electric shock. Never connect the ground cable to any of the following: gas pipes, light-
ning rods, ground cables for telephone lines and water pipes or faucets not approved by the proper
authorities. ..........................................................................................................................................
CAUTION:
• Do not place the copier on an infirm or angled surface: the copier may tip over, causing injury. .........
• Do not install the copier in a humid or dusty place. This may cause fire or electric shock. .................
• Do not install the copier near a radiator, heater, other heat source or near flammable material. This
may cause fire. ...................................................................................................................................
• Allow sufficient space around the copier to allow the ventilation grills to keep the machine as cool
as possible. Insufficient ventilation may cause heat buildup and poor copying performance. ............
• Always handle the machine by the correct locations when moving it. .................................................
• Always use anti-toppling and locking devices on copiers so equipped. Failure to do this may cause
the copier to move unexpectedly or topple, leading to injury. ..............................................................
• Avoid inhaling toner or developer excessively. Protect the eyes. If toner or developer is accidentally
ingested, drink a lot of water to dilute it in the stomach and obtain medical attention immediately.
If it gets into the eyes, rinse immediately with copious amounts of water and obtain medical atten-
tion. .....................................................................................................................................................
• Advice customers that they must always follow the safety warnings and precautions in the copier’s
instruction handbook. .........................................................................................................................

2. Precautions for Maintenance
WARNING
• Always remove the power plug from the wall outlet before starting machine disassembly. ................
• Always follow the procedures for maintenance described in the service manual and other related
brochures. ..........................................................................................................................................
• Under no circumstances attempt to bypass or disable safety features including safety mechanisms
and protective circuits. ........................................................................................................................
• Always use parts having the correct specifications. ............................................................................
• Always use the thermostat or thermal fuse specified in the service manual or other related brochure
when replacing them. Using a piece of wire, for example, could lead to fire or other serious acci-
dent. ...................................................................................................................................................
• When the service manual or other serious brochure specifies a distance or gap for installation of a
part, always use the correct scale and measure carefully. ..................................................................
• Always check that the copier is correctly connected to an outlet with a ground connection. ...............
• Check that the power cable covering is free of damage. Check that the power plug is dust-free. If it
is dirty, clean it to remove the risk of fire or electric shock. .................................................................
• Never attempt to disassemble the optical unit in machines using lasers. Leaking laser light may
damage eyesight. ...............................................................................................................................
• Handle the charger sections with care. They are charged to high potentials and may cause electric
shock if handled improperly. ...............................................................................................................
CAUTION
• Wear safe clothing. If wearing loose clothing or accessories such as ties, make sure they are safely
secured so they will not be caught in rotating sections. ......................................................................
• Use utmost caution when working on a powered machine. Keep away from chains and belts. ..........
• Handle the fixing section with care to avoid burns as it can be extremely hot. ..................................
• Check that the fixing unit thermistor, heat and press rollers are clean. Dirt on them can cause
abnormally high temperatures. ...........................................................................................................

• Do not remove the ozone filter, if any, from the copier except for routine replacement. ......................
• Do not pull on the AC power cord or connector wires on high-voltage components when removing
them; always hold the plug itself. ........................................................................................................
• Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a
cable cover or other appropriate item. ................................................................................................
• Treat the ends of the wire carefully when installing a new charger wire to avoid electric leaks. ..........
• Remove toner completely from electronic components. .....................................................................
• Run wire harnesses carefully so that wires will not be trapped or damaged. ......................................
• After maintenance, always check that all the parts, screws, connectors and wires that were
removed, have been refitted correctly. Special attention should be paid to any forgotten connector,
trapped wire and missing screws. .......................................................................................................
• Check that all the caution labels that should be present on the machine according to the instruction
handbook are clean and not peeling. Replace with new ones if necessary. .......................................
• Handle greases and solvents with care by following the instructions below: ......................................
· Use only a small amount of solvent at a time, being careful not to spill. Wipe spills off completely.
· Ventilate the room well while using grease or solvents.
· Allow applied solvents to evaporate completely before refitting the covers or turning the power
switch on.
· Always wash hands afterwards.
• Never dispose of toner or toner bottles in fire. Toner may cause sparks when exposed directly to
fire in a furnace, etc. ...........................................................................................................................
• Should smoke be seen coming from the copier, remove the power plug from the wall outlet immedi-
ately. ...................................................................................................................................................
3. Miscellaneous
WARNING
• Never attempt to heat the drum or expose it to any organic solvents such as alcohol, other than the
specified refiner; it may generate toxic gas. ........................................................................................
• Keep the machine away from flammable liquids, gases, and aerosols. A fire or an electric shock
might occur. ........................................................................................................................................

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2PS/2PT-1
CONTENTS
1-1 Specifications
1-1-1 Specifications ........................................................................................................................1-1-1
1-1-2 Parts names ..........................................................................................................................1-1-3
(1) Machine (front side)..........................................................................................................1-1-3
(2) Machine (rear side)...........................................................................................................1-1-4
(3) Operation panel................................................................................................................1-1-5
1-1-3 Machine cross section...........................................................................................................1-1-6
1-2 Installation
1-2-1 Installation environment.........................................................................................................1-2-1
1-2-2 Unpacking..............................................................................................................................1-2-2
1-2-3 Installing the expansion memory (option)............................................................................1-2-10
1-2-4 Installing the SSD (option for 26/28 ppm model only) .........................................................1-2-12
1-2-5 Installing the network interface card (option).......................................................................1-2-13
1-3 Service Mode
1-3-1 Service mode.........................................................................................................................1-3-1
(1) Executing a service mode ................................................................................................1-3-1
(2) Description of service mode.............................................................................................1-3-2
(3) Printing an event log.......................................................................................................1-3-15
1-4 Troubleshooting
1-4-1 Paper misfeed detection........................................................................................................1-4-1
(1) Paper misfeed indication ..................................................................................................1-4-1
(2) Paper misfeed detection condition ...................................................................................1-4-2
1-4-2 Self-diagnostic function .........................................................................................................1-4-6
(1) Self-diagnostic function ....................................................................................................1-4-6
(2) Self diagnostic codes........................................................................................................1-4-7
1-4-3 Image formation problems...................................................................................................1-4-29
(1) No image appears (entirely white)..................................................................................1-4-30
(2) No image appears (entirely black)..................................................................................1-4-30
(3) A specific color is printed solid. ......................................................................................1-4-31
(4) The back side gets dirty..................................................................................................1-4-31
(5) Image is too light. ...........................................................................................................1-4-31
(6) The background is colored. ............................................................................................1-4-32
(7) White streaks are printed vertically.................................................................................1-4-32
(8) Black streaks are printed vertically.................................................................................1-4-32
(9) Streaks are printed horizontally......................................................................................1-4-33
(10) Spots are printed............................................................................................................1-4-33
(11) The leading edge of image begins to print too early or too late......................................1-4-33
(12) Paper is wrinkled............................................................................................................1-4-33
(13) Offset occurs. .................................................................................................................1-4-34
(14) Part of image is missing. ................................................................................................1-4-34
(15) Fusing is loose................................................................................................................1-4-34
(16) Colors are printed offset to each other...........................................................................1-4-35
1-4-4 Electric problems.................................................................................................................1-4-36
1-4-5 Mechanical problems...........................................................................................................1-4-39

2PS/2PT-1
1-5 Assembly and disassembly
1-5-1 Precautions for assembly and disassembly...........................................................................1-5-1
(1) Precautions.......................................................................................................................1-5-1
(2) Drum.................................................................................................................................1-5-1
(3) Toner................................................................................................................................1-5-1
(4) How to tell a genuine Kyocera toner container.................................................................1-5-2
1-5-2 Outer covers..........................................................................................................................1-5-3
(1) Detaching and refitting the top cover................................................................................1-5-3
(2) Detaching and refitting the right rear cover, right cover and right lower cover .................1-5-5
(3) Detaching and refitting the left rear cover, left cover and left lower cover........................1-5-8
(4) Detaching and refitting the inner cover...........................................................................1-5-10
1-5-3 Paper feed section...............................................................................................................1-5-12
(1) Detaching and refitting the retard roller unit ...................................................................1-5-12
(2) Detaching and refitting the paper feed roller unit............................................................1-5-14
(3) Detaching and refitting the MP paper feed roller............................................................1-5-16
1-5-4 Developing section ..............................................................................................................1-5-18
(1) Detaching and refitting the developing unit ....................................................................1-5-18
1-5-5 Drum section .......................................................................................................................1-5-20
(1) Detaching and refitting the drum unit..............................................................................1-5-20
1-5-6 Transfer/Separation section ................................................................................................1-5-21
(1) Detaching and refitting the intermediate transfer unit.....................................................1-5-21
(2) Detaching and refitting the transfer roller unit.................................................................1-5-24
1-5-7 Fuser section.......................................................................................................................1-5-25
(1) Detaching and refitting the fuser unit..............................................................................1-5-25
1-5-8 PWBs...................................................................................................................................1-5-26
(1) Detaching and refitting the engine PWB.........................................................................1-5-26
(2) Detaching and refitting the power source PWB..............................................................1-5-28
(3) Detaching and refitting the main PWB............................................................................1-5-29
(4) Detaching and refitting the high voltage PWB................................................................1-5-34
1-5-9 Drive section........................................................................................................................1-5-35
(1) Detaching and refitting the MP feed drive unit................................................................1-5-35
(2) Detaching and refitting the drum/developing drive unit ..................................................1-5-36
(3) Detaching and refitting the paper feed drive unit............................................................1-5-38
(4) Detaching and refitting the fuser pressure drive unit......................................................1-5-39
(5) Detaching and refitting the middle transfer drive unit.....................................................1-5-41
1-5-10 Optical section.....................................................................................................................1-5-43
(1) Detaching and refitting the laser scanner unit ................................................................1-5-43
1-5-11 Others..................................................................................................................................1-5-46
(1) Detaching and refitting the paper conveying unit ...........................................................1-5-46
(2) Detaching and refitting the operation panel....................................................................1-5-48
(3) Detaching and refitting the power source inlet ...............................................................1-5-49
(4) Direction of installing the principal fan motors................................................................1-5-51
1-6 Requirements on PWB Replacement
1-6-1 Upgrading the firmware .........................................................................................................1-6-1
1-6-2 Remarks on engine PWB replacement .................................................................................1-6-3

2PS/2PT-1
2-1 Mechanical Construction
2-1-1 Paper feed/conveying section ...............................................................................................2-1-1
(1) Cassette paper feed section (21/23 ppm model)..............................................................2-1-1
(2) Cassette paper feed section (26/28 ppm model)..............................................................2-1-2
(3) MP tray paper feed section...............................................................................................2-1-4
(4) Paper conveying section ..................................................................................................2-1-6
2-1-2 Drum section .........................................................................................................................2-1-8
2-1-3 Developing section ..............................................................................................................2-1-10
2-1-4 Laser scanner section .........................................................................................................2-1-12
2-1-5 Transfer/Separation section ................................................................................................2-1-14
(1) Intermediate transfer unit section...................................................................................2-1-14
(2) Secondary transfer roller section....................................................................................2-1-16
2-1-6 Fuser section.......................................................................................................................2-1-17
2-1-7 Eject/Feedshift section ........................................................................................................2-1-19
2-1-8 Duplex conveying section....................................................................................................2-1-21
2-2 Electrical Parts Layout
2-2-1 Electrical parts layout ............................................................................................................2-2-1
(1) PWBs................................................................................................................................2-2-1
(2) Switches and sensors.......................................................................................................2-2-4
(3) Motors...............................................................................................................................2-2-6
(4) Others...............................................................................................................................2-2-7
2-3 Operation of the PWBs
2-3-1 Power source PWB ...............................................................................................................2-3-1
2-3-2 Engine PWB ..........................................................................................................................2-3-3
2-3-3 Main PWB............................................................................................................................2-3-13
2-3-4 Drum relay PWB..................................................................................................................2-3-18
2-4 Appendixes
2-4-1 Appendixes............................................................................................................................2-4-1
(1) Maintenance kits (26/28 ppm model only)........................................................................2-4-1
(2) Repetitive defects gauge..................................................................................................2-4-2
(3) Firmware environment commands ...................................................................................2-4-3
(4) Maintenance Commands..................................................................................................2-4-9
(5) Wiring diagram ...............................................................................................................2-4-10

2PS/2PT
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2PS/2PT-3
1-1-1
1-1 Specifications
1-1-1 Specifications
Item Specifications
21/23 ppm model (A4/Letter) 26/28 ppm model (A4/Letter)
Type Desktop
Printing method Electrophotography by semiconductor laser, tandem (4) drum system
Paper weight Cassette 60 to 163 g/m2
MP tray 60 to 220 g/m2
Paper type
Cassette Plain, Recycled, Preprinted, Bond, Color (Colour), Prepunched,
Letterhead, Thick, High quality, Custom 1 to 8 (Duplex: Same as simplex)
MP tray Plain, Transparency, Vellum, Labels, Recycled, Preprinted, Bond, Cardstock, Color (Colour), Prepunched, Letterhead, Thick, Envelope,
Coated, High quality, Custom 1 to 8
Paper size
Cassette A4, A5, A6, B5, ISO B5, Letter, Legal, Statement, Executive, Oficio II, Folio,
16K, Envelope C5, Custom
MP tray
A4, A5, A6, B5, ISO B5, B6, Letter, Legal, Statement, Executive, Oficio II,
Folio, 16K, Envelope #10, Envelope #9, Envelope #6, Envelope Monarch,
Envelope DL, Envelope C5, Postcards, Return postcard, Youkei 2,
Youkei 4, Custom, 216 x 340 mm
Copying
speed
Simplex
A4 : 21 sheets/min
Letter : 23 sheets/min
Legal : 18 sheets/min
B5 : 23 sheets/min
A5 : 23 sheets/min
A6 : 23 sheets/min
A4 : 26 sheets/min
Letter : 28 sheets/min
Legal : 23 sheets/min
B5 : 28 sheets/min
A5 : 28 sheets/min
A6 : 28 sheets/min
Duplex A4 : 11 sheets/min Letter : 11 sheets/min
Legal : 10 sheets/min
A4 : 13 sheets/min
Letter : 13 sheets/min
Legal : 12 sheets/min
First print time
(A4, feed from cassette) B/W : 10.5 s or less Color: 12.0 s or less B/W : 9.0 s or less Color: 10.5 s or less
(Excluding time for system stabilization immediately after turning on the
main power.)
Warm-up time
(22 °C/71.6 °F, 60% RH)
Power on : 32 s or less
Low power mode : 13 s or less
Sleep mode : 18 s or less
Power on : 29 s or less
Low power mode : 11 s orless
Sleep mode : 20 s or less
Paper
capacity Cassette 250 sheets (80g/m2) 500 sheets (80g/m2)
MP tray 50 sheets (80 g/m2) 50 sheets (80 g/m2)
Output tray capacity 250 sheets (80g/m2)
Photoconductor OPC drum (diameter 30 mm)
Image write system Semiconductor laser
Charging system Charger roller
Developing system Touch down developing system Developer: 2-component
Toner replenishing: Automatic from the toner container

2PS/2PT-3
1-1-2
NOTE: These specifications are subject to change without notice.
Transfer system Primary: Transfer belt
Secondary: Transfer roller
Separation system Small diameter separation
Cleaning system Drum: Counter blade
Charge erasing system Exposure by cleaning lamp (LED)
Fusing system Heat and pressure fusing with the heat roller and the press roller Heat source: halogen heater
Abnormally high temperature protection devices: thermostat
CPU PowerPC465S (667MHz)
Main
memory Standard 512 MB
Maximum 1536 MB
Operating system
Windows 2000, Windows XP, Windows XP Professional
Windows Server 2003, Windows Server 2003 x64 Edition
Windows Vista x86 Edition, Windows Vista x64 Edition
Windows 7 x86 Edition, Windows 7 x64 Edition, Windows Server 2008
Windows Server 2008 x64 Edition, Windows Server 2012 x64 Edition
Apple Macintosh OS 10.x
Interface Standard Network interface: 1 (10BASE-T/100BASE-TX/1000BASE-T)
USB interface connector: 1 (USB Hi-speed)
USB host: 1 (USB Hi-speed) USB host: 2 (USB Hi-speed)
Option e-KUIO slot: 1
Page description language PRESCRIBE
Resolution 600 dpi
Operating
environment
Temperature 10 to 32.5 °C/50 to 90.5 °F
Humidity 15 to 80% RH
Altitude 2,500 m/8,202 ft or less
Brightness 1,500 lux or less
Dimensions (W ×D ×H) 390 × 523 × 370 mm
15 3/8 × 20 9/16 × 14 9/16” 390 × 523 × 397 mm 15 3/8 × 20 9/16 × 15 5/8”
Weight Approx. 29.3 kg / 64.6 lbs
(with toner container) Approx. 30.2 kg / 66.6 lbs (with toner container)
Space required (W ×D) 440 × 1020 mm (using MP tray)
17 5/16 × 40 3/16” (using MP tray)
Rated input 120 V AC, 60 Hz, max. 8.5 A
220 - 240 V AC, 50/60 Hz, max. 4.5 A
Options Paper feeder × 2, Expanded mem- ory, Network interface card Paper feeder × 3, Expanded mem- ory, SSD(HD-6/7), Network inter-
face card
Item Specifications
21/23 ppm model (A4/Letter) 26/28 ppm model (A4/Letter)

2PS/2PT
1-1-3
1-1-2 Parts names
(1) Machine (front side)
Figure 1-1-1
4
1
5
13
3
2
891011
6
712
14
1. Operation panel
2. Top tray (Top cover)
3. Paper stopper
4. MP (Multi-Purpose) tray
5. Cassette
6. USB memory slot
7. Main power switch
8. Toner container K
9. Toner container M
10. Toner container C
11. Toner container Y
12. Waste toner cover
13. Waste toner box
14. Lock release button

2PS/2PT
1-1-4
(2) Machine (rear side)
Figure 1-1-2
20
19
18
21
16
15
17
23
25
22
24
15. Rear cover
16. Rear cover lever
17. IF cover
18. Memory cover
19. Power cord cover
20. Paper conveying unit
21. Power cord connector
22. Network interface connector
23. USB interface connector
24. USB memory slot
25. Interface slot

2PS/2PT
1-1-5
(3) Operation panel
Figure 1-1-3
1 65 7
9
8432
1. Message display
2. Ready indicator
3. Data indicator
4. Attention indicator
5. Cursor keys
6. MENU key
7. Cancel key
8. OK key
9. GO key

2PS/2PT
1-1-6
1-1-3 Machine cross section
Figure 1-1-4
13
15
20
9
5
14
2
18
17
19
3
16
12
4
811 7 10 6
Paper path
26/28 ppm
model
21/23 ppm
model
1
1
1. Cassette paper feed section
2. MP tray paper feed section
3. Paper conveying section
4. Laser scanner unit KM
5. Laser scanner unit CY
6. Drum unit K
7. Drum unit M
8. Drum unit C
9. Drum unit Y
10. Developing unit K
11. Developing unit M
12. Developing unit C
13. Developing unit Y
14. Toner container section
15. Primary transfer section
16. Secondary transfer/Separa-
tion sections
17. Fuser section
18. Eject/Feed shift sections
19. Duplex section
20. Operation panel section