Duplo 660P Maintenance Manual

MAINTENANCE

MANUAL

PAPER CUTTER

660P

P/N 660PSMV2

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TABLE OF CONTENTS

Section 1 - Specifications

Section 2 - Maintenance & Mechanical Adjustments

Lubrication ............................................................................................................ 2-2

Main Worm Gear and Drive Block ........................................................... 2-2

Knife and Clamp Guides .......................................................................... 2-2

Hydraulic Oil ............................................................................................ 2-2

Blade Sharpening .................................................................................................. 2-2

Removal and Installation of the Cutting Tables ........................................................ 2-3

Cutting Table Squareness ...................................................................................... 2-4

Cutting Table Alignment ......................................................................................... 2-4

Backgauge Alignment ............................................................................................ 2-5

Cutting Accuracy .................................................................................................. 2-5

Section 3 - Troubleshooting

Troubleshooting Tables........................................................................................... 3-2

Section 4 - Hydraulics

Hydraulic Adjustments ........................................................................................... 4-2

Hydraulic Diagram................................................................................................. 4-4

Section 5 - Electrical Description & Adjustments

Start Up and Shut Down Procedure....................................................................... 5-2

Set Up for Programmatic MKII............................................................................... 5-3

Option Settings Table ............................................................................................. 5-4

Rear Calibration Point (Cutting Accuracy)............................................................. 5-5

PLC Input/Output Table .......................................................................................... 5-6

Main Electrical Diagram Key ................................................................................. 5-7

PLC Electrical Diagram ......................................................................................... 5-8

Programmatic MKII Panel Circuit Diagram ............................................................ 5-9

Backgauge Motor Drive Circuit Diagram ............................................................... 5-9

IMPORTANT

THIS DEVICE MUST BE OPERATED WITHIN THE SPECIFIED AC LINE VOLTAGE. IF THE AC POWER

FALLS OUTSIDE OF THE SPECIFIED LIMITS, A DEDICATED POWER LINE MUST BE USED. IF THE

POWER STILL DOES NOT FALL WITHIN SPECIFIED GUIDELINES A POWER CONVERSION (BUCK/

BOOST) TRANSFORMER MUST BE USED. FAILURE TO PROVIDE THE PROPER POWER WILL

RESULT IN POOR OR NO OPERATION.

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IMPORTANT NOTICE

The Duplo 660P paper cutting guillotine which you have received has been thoroughly inspected and

tested.

Please Note:

* The use of this machine is limited to cutting paper and chip board only.

Please ensure that all service personnel read these instructions thoroughly before working on the 660P.

SAFETY

1. Power guillotines must be serviced only by trained and reliable persons.

2. Defects and damage on cutting machines which affect the safe operation must be dealt with immediately.

Until ALL faults have been corrected, the cutter must not be operated.

3. Regular inspection of all safety devices must be made.

4. Transportation of guillotine knives should only be allowed in the specially designed wooden carrying

cases supplied.

5. To prevent serious injury only one person may operate the machine at a time.

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SECTION 1

SPECIFICATIONS

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SECTION 1 - SPECIFICATIONS

GENERAL

Cutting Width ......................................................................... 26.5”

Maximum Paper Pile Height ................................................... 3.93”

Minimum Cut Size without False Clamp .................................. 0.79”

Minimum Cut Size with False Clamp ...................................... 2”

Maximum Length (back table) ................................................ 26.5”

Minimum Clamp Pressure ...................................................... 300 lbs.

Maximum Clamp Pressure ..................................................... 2,500 lbs.

Programmable Memory Settings ............................................ 9

Weight ................................................................................... 1,124 lbs.

Operating Temperature........................................................... 32 - 131 °F

Operating Humidity ................................................................ 45 - 85 % Relative Humidity

Knife Tip Angle....................................................................... First Bevel 22° Second Bevel 24°

Fluids

Hydraulic Fluid ....................................................................... Type ISO 68 & 32

Lubricating Oil ........................................................................ SAE 30 & 40

POWER REQUIREMENTS

Voltage ................................................................................... 220 - 240 VAC

Phase .................................................................................... Single

Current .................................................................................. 20 Amperes

DIMENSIONS

Length .................................................................................... 63”

Width ..................................................................................... 60”

Height .................................................................................... 57”

Table Height ........................................................................... 34.64”

* Specifications subject to change without notice

660P Cutter

1 - 2

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SECTION 2

MAINTENANCE

&

ADJUSTMENTS

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SECTION 2 - MAINTENANCE & ADJUSTMENTS

There are several locations that require periodic oil

or grease applications. The motors, however, have

high quality sealed bearings that do not require

lubrication.

OILING THE MAIN WORM GEAR AND

DRIVE BLOCK

Perform this procedure approximately every three

months.

1. Fill the automatic oiling cup (located on the top

right of the main portion of the cutter) halfway

with a high quality machine oil.

2. Adjust the flow to allow one drop of oil every one

second.

3. Use the MKII controller to move the backgauge

it’s maximum limits of forward and reverse travel.

4. Turn off the flow of oil when the worm gear is

thoroughly oiled.

5. Add more oil and repeat the process if the worm

gear appears to be dry.

KNIFE AND CLAMP GUIDES

Perform this procedure as necessary.

1. Remove the front cover.

2. Apply grease to all exposed areas of the guide

surfaces.

2. Turn the green knife change switch to the right

(knife change position).

3. Press and hold both yellow cut push-buttons. The

clamp and knife will drop down and stay in the

down position.

4. Apply grease to the remaining surfaces.

5. Turn the knife change switch to the left.

HYDRAULIC OIL

Due to the hydraulic circuit’s limited duty cycle, the

oil should last for the life of the machine. However, if

there was a leak, top off the hydraulic oil as indicated

by the sight glass located behind the front panel on

the oil reservoir.

BLADE SHARPENING

The cutting blade requires sharpening and must not

be neglected. Several symptoms may be present

indicating the blade must be sharpened or replaced.

Signs that the cutting blade requires sharpening:

1) Loud sound while blade cuts paper

2) Paper “tears” rather than makes clean cuts

2) Knife won’t cut thick stacks of paper

3) Cutter beeps while cutting paper

Sharpening specification: 22° with 2° second bevel

660P Cutter

2 - 2

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SECTION 2 - MAINTENANCE & ADJUSTMENTS

REMOVAL AND INSTALLATION OF THE

CUTTING BED

WARNING

THE CUTTING TABLES ARE VERY

HEAVY. IMPROPER HANDLING MAY

CAUSE SERIOUS INJURY. USE

EXTREME CARE WHILE PERFORMING

THIS PROCEDURE.

DISASSEMBLY

1. Remove the front lower cover.

2. Remove the back lower cover.

3. Remove the backgauge drive cover.

4. Remove the plastic wheel (used for fine

adjustments).

5. Cut and remove all of the wire ties located

underneath the right side of the cutting table.

6. Remove the two bolts securing the cutting buttons

cover. They are located on the underside of the

cutting table.

7. Remove the adjusting bolt from the left underside

of the cutting table.

8. Remove the two vertically oriented bolts holding

the front table to the main frame.

9. Remove the two horizontally oriented bolts that

hold the front table to the rear table.

10. Using an assistant, remove the front table and

CAREFULLY set it aside.

11. Remove the two vertically oriented bolts holding

the rear table to the main frame.

12. Using an assistant, remove the rear table and

CAREFULLY set it aside.

REASSEMBLY

1. Using an assistant, CAREFULLY place the rear

table in the approximate position and secure it

with the two bolts. Do not tighten the bolts just

make them snug.

2. Attach the two alignment jigs from the supplied

tool kit to the two front table mounting holes. The

bolt must go from the floor, up through the frame

and then through the jig. Make sure the lip on

each jig is facing down and resting on the edge

of the cutter frame towards the operator side.

3. Have an assistant push the rear table firmly

against the two alignment jigs and tighten the two

bolts holding the rear table. Make sure there is

no gaps between the jigs and the rear table.

4. Remove the two jigs.

5. CAREFULLY reinstall the front table reversing

steps 1 through 10 of the DISASSEMBLY

instructions.

6. Test for squareness.

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SECTION 2 - MAINTENANCE & ADJUSTMENTS

CUTTING TABLE SQUARENESS

The cutting table must be properly aligned to the

cutting line. If there is any misalignment adjust the

table accordingly.

TESTING FOR CUTTING TABLE SQUARENESS

1. Check the cutting table alignment by any of the

following methods:

a) Check the cutting stick for a notch that has

been cut by the blade. If the notch is not parallel

to the edge of the stick the table is not aligned

properly.

b) Place a small block under the clamp. Lower

the clamp and knife using the blade change

switch. Use a square to check the alignment

of the blade to the sides of the cutting table.

CUTTING TABLE ALIGNMENT

1. Determine what correction is necessary (see

“Testing for Cutting Table squareness”).

2. Remove the front and rear covers (four Allen

screws each).

3. Loosen, but do not remove, the two front table

bolts and the left rear bolt (19mm) that secure

the cutting table to the cutter frame, see

Figures

1 and 2

.

4. Loosen the lock nut on the table adjusting bolt. It

is located underneath the table on the front left

side.

5. Adjust the table adjusting bolt until the table is

square.

6. Test for squareness. When satisfactory, lock the

bolts from steps 2 and 3.

Figure 1 - Cutting Table Bolts

Front View (front cover removed)

Figure 2 - Cutting Table Bolts

Rear View (rear cover removed)

660P Cutter

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SECTION 2 - MAINTENANCE & ADJUSTMENTS

BACKGAUGE SQUARENESS

The backgauge must be parallel to the cutting line.

If there is any misalignment adjust the backgauge

accordingly. Test cutting table squareness before

testing the backgauge.

TESTING FOR BACKGAUGE SQUARNESS

1. Cut several sheets of paper at the same time.

Align them against the right side of the cutting

area and evenly against the backgauge.

2. Remove and discard the pieces closest to the

operator.

3. Turn the remaining sheets over and push them

against the left side of the cutting area and

against the backgauge.

4. Observe any excess trimmings from the cut. If

there are any pieces left over, perform the

backgauge alignment.

BACKGAUGE ALIGNMENT

1. Determine what correction is necessary (see

“Testing for Backgauge Squareness”).

2. Remove the two screws A, see Figure 3.

3. Remove screw A and remove the backgauge

drive cover, see Figure 4.

3. Loosen, but do not remove, the two bolts B on

the left side of the backgauge, see Figure 3.

4. Loosen, but do not remove, the two nuts B on

the right side of the backgauge, see Figure 5.

5. Adjust the two bolts as necessary to “square

up’ the backgauge to the cutting line.

6. Test for squareness. When satisfactory, lock

the bolts from steps 3 and 4.

7. Reinstall the backgauge drive cover.

CUTTING ACCURACY

See the Electrical Section for details on setting the

“Rear Calibration Point.”

Figure 3 - Backgauge Drive Cover Rear Bolts

A

B

A

B

Figure 4 - Backgauge Drive Cover Rear Bolts

A

B

Figure 5 - Backgauge Adjusting Bolts

660P Cutter

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SECTION 3

TROUBLESHOOTING

IMPORTANT

THIS DEVICE MUST BE OPERATED WITHIN THE SPECIFIED AC LINE VOLTAGE. IF

THE AC POWER FALLS OUTSIDE OF THE SPECIFIED LIMITS, A DEDICATED POWER

LINE MUST BE USED. IF THE POWER STILL DOES NOT FALL WITHIN SPECIFIED

GUIDELINES A POWER CONVERSION (BUCK/BOOST) TRANSFORMER MUST BE

USED. FAILURE TO PROVIDE THE PROPER POWER WILL RESULT IN POOR OR

NO OPERATION.

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SECTION 3 - TROUBLESHOOTING

SYMPTOMS CAUSE CORRECTION

1. The cutter will not power on Power cord is not connected. Connect the power cord.

F1 or F2 fuse is blown. Check and replace F1 or F2.

2. Main motor will not run. The overload protection device

(OL) is activated.

Check the overload

protection device (OL).

The knife timer control (T1 - cut

depth control) is defective.

Check the knife timer control

3. The knife cannot be engaged. Have not started the main motor. Turn the main switch to the

Start position.

The safety beam(s) are blocked. Clear any obstructions in the

beam path.

Knife down push button(s) (PB-1

and PB-2) are defective.

Check the knife down push

button(s) (PB-1 and PB-2).

The knife timer control (T1 - Cut

depth control) is defective.

Check the knife timer control

No oil pressure. Check or change the clutch.

4. Main motor clutch doesn't

engage.

Loud noise from the clutch area. Check and adjust the gap of

clutch.

No clutch action. Check the bridge rectifier

(RF).

5. Knife down completely, but

cannot return to top position.

Upper limit switch (LS-U) is

defective.

Check the upper limit switch

(LS-U).

The safety beam(s) are blocked. Clear any obstructions in the

beam path.

Knife change switch (PB-K) is

broken or in the wrong position

Verify position and replace

the knife change selector

(PB-K) if necessary.

Knife down push buttons (PB-1,

PB-2) are broken.

Check the knife down push

buttons (PB-1 and PB-2).

Knife adjustment timer (T1 - cut

depth control) does not work.

Change the new knife

adjustment timer

Knife position is too low. Adjust knife height.

6. Clamp doesn't move. Oil pressure is too low. Perform hydraulic

adjustments.

IMPORTANT

THIS DEVICE MUST BE OPERATED WITHIN THE SPECIFIED AC LINE VOLTAGE. IF THE AC POWER

FALLS OUTSIDE OF THE SPECIFIED LIMITS, A DEDICATED POWER LINE MUST BE USED. IF THE

POWER STILL DOES NOT FALL WITHIN SPECIFIED GUIDELINES A POWER CONVERSION (BUCK/

BOOST) TRANSFORMER MUST BE USED. FAILURE TO PROVIDE THE PROPER POWER WILL RESULT

IN POOR OR NO OPERATION.

660P Cutter

3 - 2

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SECTION 3 - TROUBLESHOOTING

6. Continued from previous page The same as the problem of knife

cannot be engaged.

See corrective action above

for knife cannot be engaged.

Upper limit switch (LS-U) not

released.

Check switch LS-U.

7. Clamp will not return to the up

position

Oil pressure is too low. Perform hydraulic

adjustments.

The knife and clamp UP control

(LS-U) does not work.

Check the knife and clamp

up control (LS-U).

8. Power com es on but the

backgauge drive motor does

not run.

Poor connection to the backgauge

drive motor

Check the connection to the

backgauge drive motor.

The backgauge low speed,

forward or backward relay is

defective

Check the backgauge low

speed, forward or backward

relay (R1, R2, and R3).

The bridge rectifier (GF) is

defective.

Check the bridge rectifier

(GF).

Fuses (F1 and F2) are blown. Check the fuses.

9. Main motor runs too slow and

eventually the overload circuit

shuts off the motor

The centrifugal switch or starter

capacitor are defective

Check the centrifugal switch

or starter capacitor (located

under the end cover of the

main motor housing).

10. Fuses F1 and/or F2 are blown. The main motor centrifugal switch

or capacitor is defective.

Check the centrifugal switch

or capacitor inside main

motor (located under the end

cover of the main motor

housing).

The bridge rectifier GF is shorted Check the bridge rectifier

GF.

The bridge rectifier RF is shorted Check the bridge rectifier

RF.

The backgauge drive motor is

locked.

Check that the backgauge

table moves freely.

The back

g

au

g

e rear lim it switch is

defective.

Check the backgauge rear

lim it sw itch (LS-S).

11. The cutter beeps constantly

and the blade will not return to

the top position.

The cutter power was rem oved

during a cutting cycle.

Press either one of the

yellow cutter buttons.

12. During a cut the cutter beeps The knife is dull Sharpen the knife

The clamp pressure is to low. Perform the clamp pressure

adjustment.

Trying to cut too much paper. Reduce the amount of paper

being cut.

IMPORTANT

THIS DEVICE MUST BE OPERATED WITHIN THE SPECIFIED AC LINE VOLTAGE. IF THE AC POWER

FALLS OUTSIDE OF THE SPECIFIED LIMITS, A DEDICATED POWER LINE MUST BE USED. IF THE

POWER STILL DOES NOT FALL WITHIN SPECIFIED GUIDELINES A POWER CONVERSION (BUCK/

BOOST) TRANSFORMER MUST BE USED. FAILURE TO PROVIDE THE PROPER POWER WILL RESULT

IN POOR OR NO OPERATION.

660P Cutter

3 - 3

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SECTION 4

HYDRAULIC ADJUSTMENTS

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SECTION 4 - HYDRAULIC ADJUSTMENTS

18

TAP 1

17

06

09

TAP 2

PRESSURE

GAUGE 2

PERFORM THE FOLLOWING ADJUSTMENTS IN THE ORDER SPECIFIED

Please Note: You will need an assistant to push the yellow cutter buttons during these adjustments.

VALVE 17 - RELIEF VALVE

ADJUST PRESSURE READING GAUGE

VALVE 17

95 +/- 5 kg/cm

2

PURPOSE: This adjustment sets the maximum

pressure for the hydraulic system. It prevents motor

overload.

PROCEDURE:

1. Supply hydraulic pressure to gauge 2 by opening

tap 2.

2. Shut off the supply of hydraulic pressure to the

pressure gauge on the front of the machine by

closing tap 1. Note the gauge is not shown in the

illustration above.

3. Turn on the 660 cutter.

4. Activate the knife and the clamp by having an

assistant push both yellow cutting buttons

simultaneously.

5. Loosen the lock nut on the relief valve 17.

6. While observing the reading on gauge 2, adjust

valve 17 until the pressure indicated is 95 ± 5

kg/cm

2

.

7. Tighten the lock nut on valve 17.

8. Close tap 2 and open tap 1.

VALVE 06 - RELIEF VALVE

ADJUST PRESSURE READING GAUGE

VALVE 06

30

+/-

3 kg/cm

2

PURPOSE: Valve 06 adjusts the low pressure for

the foot pedal and the blade change mode.

PROCEDURE:

1. Supply hydraulic pressure to gauge 2 by opening

tap 2.

2. Loosen the lock nut on the relief valve 06.

3. Have an assistant activate the clamp by pushing

the foot pedal down.

4. While observing the reading on gauge 2, adjust

valve 06 until the pressure indicated is 30 ± 3

kg/cm

2

.

5. Tighten the lock nut on the relief valve 06.

6. Close tap 2.

660P CUTTER

4 - 2

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SECTION 4 - HYDRAULIC ADJUSTMENTS

VALVE 18 - SEQUENCING VALVE

ADJUST PRESSURE READING GAUGE

VALVE 18

60

+/-

1 kg/cm

2

1

OPERATOR CLAMP CONTROL

50

+/-

10 kg/cm

2

OPERATOR

PURPOSE: Valve 18 adjusts the clamp pressure.

PROCEDURE:

1. Loosen the lock ring and turn the outside

clamp pressure control fully clockwise.

2. Activate the knife and the clamp by having

an assistant push both yellow cutting buttons

simultaneously.

3. Loosen the lock nut on valve 18.

4. While observing the reading on gauge 1,

adjust valve 18 until the pressure indicated

is 60 ± 1 kg/cm

2

.

5. Tighten the lock nut on valve 18.

6. While observing gauge 1, activate the clamp

by pushing the foot pedal down.

7. Adjust the operator clamp pressure control

to 50 ± 10 kg/cm

2.

8. Tighten the operator clamp pressure control

lock ring.

VALVE 09 - SEQUENCING VALVE

PURPOSE: Valve 09 adjusts the return timing

between the knife and the clamp. The clamp should

return as soon as the knife reaches the home

position.

PROCEDURE:

1. Loosen the lock nut on valve 09.

2. Activate the knife and the clamp by having

an assistant push both yellow cutting buttons

simultaneously.

3. Observe the return rate of the knife and

clamp.

4. Adjust valve 09 according to the following

guidelines:

the clamp moves first - the pressure

is too high.

If the clamp stays down - the

pressure is too low.

5. Tighten the lock knob on valve 09.

Operator

Pressure

Gauge

Lock Knob

Operator Clamp

Pressure Adjust

Knob

Operator Clamp Control

660P CUTTER

4 - 3

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SECTION 4 - HYDRAULIC ADJUSTMENTS

Hydraulic Circuit Diagram

660P CUTTER

4 - 4

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Duplo 660P Maintenance Manual

Duplo 660P Maintenance Manual

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