MAINTENANCE
MANUAL
PAPER CUTTER
660P
Copyright © 2000 Duplo USA Corporation
P/N 660PSMV2
ALL RIGHTS RESERVED
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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.
660P Cutter
2 - 3
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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
2 - 4
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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
A
A
B
B
Figure 5 - Backgauge Adjusting Bolts
660P Cutter
2 - 5
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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
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
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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