Duplo 660p Maintenance Manual

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com
MAINTENANCE
MANUAL
PAPER CUTTER
660P
Copyright © 2000 Duplo USA Corporation

P/N 660PSMV2 ALL RIGHTS RESERVED
https://www.supplychimp.com
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.
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.
SECTION 1
SPECIFICATIONS
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
SECTION 2
MAINTENANCE
&
ADJUSTMENTS
SECTION 2 - MAINTENANCE & ADJUSTMENTS
There are several locations that require periodic oil

2. Turn the green knife change switch to the right
or grease applications. The motors, however, have
(knife change position).
high quality sealed bearings that do not require
lubrication.
3. Press and hold both yellow cut push-buttons. The
OILING THE MAIN WORM GEAR AND clamp and knife will drop down and stay in the
DRIVE BLOCK down position.
Perform this procedure approximately every three
months.
4. Apply grease to the remaining surfaces.
1. Fill the automatic oiling cup (located on the top
right of the main portion of the cutter) halfway 5. Turn the knife change switch to the left.
with a high quality machine oil.
HYDRAULIC OIL
2. Adjust the flow to allow one drop of oil every one
second. Due to the hydraulic circuit’s limited duty cycle, the
oil should last for the life of the machine. However, if
3. Use the MKII controller to move the backgauge there was a leak, top off the hydraulic oil as indicated
it’s maximum limits of forward and reverse travel.
by the sight glass located behind the front panel on
the oil reservoir.
4. Turn off the flow of oil when the worm gear is
thoroughly oiled.
BLADE SHARPENING
5. Add more oil and repeat the process if the worm The cutting blade requires sharpening and must not
gear appears to be dry.
be neglected. Several symptoms may be present
indicating the blade must be sharpened or replaced.
Signs that the cutting blade requires sharpening:

KNIFE AND CLAMP GUIDES 1) Loud sound while blade cuts paper
Perform this procedure as necessary. 2) Paper “tears” rather than makes clean cuts
2) Knife won’t cut thick stacks of paper
1. Remove the front cover. 3) Cutter beeps while cutting paper
Sharpening specification: 22° with 2° second bevel
2. Apply grease to all exposed areas of the guide
surfaces.
660P Cutter
2-2
REMOVAL AND INSTALLATION OF THE 10. Using an assistant, remove the front table and
CUTTING BED CAREFULLY set it aside.
WARNING 11. Remove the two vertically oriented bolts holding

THE CUTTING TABLES ARE VERY the rear table to the main frame.
HEAVY. IMPROPER HANDLING MAY
CAUSE SERIOUS INJURY. USE 12. Using an assistant, remove the rear table and
EXTREME CARE WHILE PERFORMING CAREFULLY set it aside.
THIS PROCEDURE.
REASSEMBLY
DISASSEMBLY 1. Using an assistant, CAREFULLY place the rear
1. Remove the front lower cover. table in the approximate position and secure it
with the two bolts. Do not tighten the bolts just
2. Remove the back lower cover. make them snug.
3. Remove the backgauge drive cover. 2. Attach the two alignment jigs from the supplied
tool kit to the two front table mounting holes. The
4. Remove the plastic wheel (used for fine bolt must go from the floor, up through the frame
adjustments). and then through the jig. Make sure the lip on
each jig is facing down and resting on the edge
5. Cut and remove all of the wire ties located of the cutter frame towards the operator side.
underneath the right side of the cutting table.
3. Have an assistant push the rear table firmly
6. Remove the two bolts securing the cutting buttons against the two alignment jigs and tighten the two
cover. They are located on the underside of the bolts holding the rear table. Make sure there is
cutting table. no gaps between the jigs and the rear table.
7. Remove the adjusting bolt from the left underside 4. Remove the two jigs.
of the cutting table.
5. CAREFULLY reinstall the front table reversing
8. Remove the two vertically oriented bolts holding steps 1 through 10 of the DISASSEMBLY
the front table to the main frame. instructions.
9. Remove the two horizontally oriented bolts that 6. Test for squareness.
hold the front table to the rear table.
660P Cutter
2-3
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
Figure 1 - Cutting Table Bolts
properly. Front View (front cover removed)
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).
Figure 2 - Cutting Table Bolts

3. Loosen, but do not remove, the two front table Rear View (rear cover removed)
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.
660P Cutter
2-4
BACKGAUGE SQUARENESS
The backgauge must be parallel to the cutting line.
If there is any misalignment adjust the backgauge A
accordingly. Test cutting table squareness before A
testing the backgauge.
B B
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 Figure 3 - Backgauge Drive Cover Rear Bolts
operator.
3. Turn the remaining sheets over and push them

against the left side of the cutting area and
against the backgauge.
A
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”).
Figure 4 - Backgauge Drive Cover Rear Bolts
2. Remove the two screws A, see Figure 3.
3. Remove screw A and remove the backgauge

drive cover, see Figure 4.
A
3. Loosen, but do not remove, the two bolts B on A
the left side of the backgauge, see Figure 3.
B
B
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 Figure 5 - Backgauge Adjusting Bolts
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.”
660P Cutter
2-5
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.
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 Check the overload
(OL) is activated. protection device (OL).
The knife timer control (T1 - cut Check the knife timer control
depth control) is defective.
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 Check the knife down push
and PB-2) are defective. button(s) (PB-1 and PB-2).
The knife timer control (T1 - Cut Check the knife timer control
depth control) is defective.
No oil pressure. Check or change the clutch.
4. Main motor clutch doesn't Loud noise from the clutch area. Check and adjust the gap of
engage. clutch.
No clutch action. Check the bridge rectifier
(RF).
5. Knife down completely, but Upper limit switch (LS-U) is Check the upper limit switch
cannot return to top position. defective. (LS-U).
The safety beam(s) are blocked. Clear any obstructions in the

beam path.
Knife change switch (PB-K) is Verify position and replace
broken or in the wrong position the knife change selector
(PB-K) if necessary.
Knife down push buttons (PB-1, Check the knife down push
PB-2) are broken. buttons (PB-1 and PB-2).
Knife adjustment timer (T1 - cut Change the new knife
depth control) does not work. adjustment timer
Knife position is too low. Adjust knife height.
6. Clamp doesn't move. Oil pressure is too low. Perform hydraulic

adjustments.
IMPORTANT
BOOST) TRANSFORMER MUST BE USED. FAILURE TO PROVIDE THE PROPER POWER WILL RESULT
IN POOR OR NO OPERATION.
660P Cutter
3-2
SECTION 3 - TROUBLESHOOTING
6 . C o n tin u e d fro m p re v io u s p a g e T h e s a m e a s th e p ro b le m o f k n ife S e e c o rre c tiv e a c tio n a b o v e

cannot be engaged. fo r k n ife c a n n o t b e e n g a g e d .
U p p e r lim it s w itc h (L S -U ) n o t C h e c k s w itc h L S -U .
re le a s e d .
7 . C la m p w ill n o t re tu rn to th e u p O il p re s s u re is to o lo w . P e rfo rm h yd ra u lic
p o s itio n a d ju s tm e n ts .
T h e k n ife a n d c la m p U P c o n tro l C h e c k th e k n ife a n d c la m p
(L S -U ) d o e s n o t w o rk . u p c o n tro l (L S -U ).
8 . P o w e r c o m e s o n b u t th e P o o r c o n n e c tio n to th e b a c k g a u g e C h e c k th e c o n n e c tio n to th e
b a c k g a u g e d riv e m o to r d o e s d riv e m o to r b a c k g a u g e d riv e m o to r.
n o t ru n .
T h e b a c k g a u g e lo w s p e e d , C h e c k th e b a c k g a u g e lo w
fo rw a rd o r b a c k w a rd re la y is s p e e d , fo r w a rd o r b a c k w a rd
d e fe c tiv e re la y (R 1 , R 2 , a n d R 3 ).
T h e b rid g e re c tifie r (G F ) is C h e c k th e b rid g e re c tifie r
d e fe c tiv e . (G F ).
F u s e s (F 1 a n d F 2 ) a re b lo w n . C h e c k th e fu s e s .
9 . M a in m o to r ru n s to o s lo w a n d T h e c e n trifu g a l s w itc h o r s ta rte r C h e c k th e c e n trifu g a l s w itc h

e v e n tu a lly th e o v e rlo a d c irc u it c a p a c ito r a re d e fe c tiv e o r s ta rte r c a p a c ito r (lo c a te d
s h u ts o ff th e m o to r u n d e r th e e n d c o v e r o f th e
m a in m o to r h o u s in g ).
1 0 . F u s e s F 1 a n d /o r F 2 a re b lo w n . T h e m a in m o to r c e n trifu g a l s w itc h C h e c k th e c e n trifu g a l s w itc h

o r c a p a c ito r is d e fe c tiv e . o r c a p a c ito r in s id e m a in
m o to r (lo c a te d u n d e r th e e n d
c o v e r o f th e m a in m o to r
h o u s in g ).
T h e b rid g e re c tifie r G F is s h o rte d C h e c k th e b rid g e re c tifie r
GF.
T h e b rid g e re c tifie r R F is s h o rte d C h e c k th e b rid g e re c tifie r
RF.
T h e b a c k g a u g e d riv e m o to r is C h e c k th a t th e b a c k g a u g e
lo c k e d . ta b le m o v e s fre e ly.
T h e b a c k g a u g e re a r lim it s w itc h is C h e c k th e b a c k g a u g e re a r
d e fe c tiv e . lim it s w itc h (L S -S ).
1 1 . T h e c u tte r b e e p s c o n s ta n tly T h e c u tte r p o w e r w a s re m o v e d P re s s e ith e r o n e o f th e
a n d th e b la d e w ill n o t re tu rn to d u rin g a c u ttin g c yc le . ye llo w c u tte r b u tto n s .
th e to p p o s itio n .
1 2 . D u rin g a c u t t h e c u t t e r b e e p s T h e k n ife is d u ll S h a rp e n th e k n ife
T h e c la m p p re s s u re is to lo w . P e rfo rm th e c la m p p re s s u re
a d ju s tm e n t.
T ryin g to c u t to o m u c h p a p e r. R e d u c e th e a m o u n t o f p a p e r
b e in g c u t.
IMPORTANT
BOOST) TRANSFORMER MUST BE USED. FAILURE TO PROVIDE THE PROPER POWER WILL RESULT
IN POOR OR NO OPERATION.
660P Cutter
3-3
SECTION 4
HYDRAULIC ADJUSTMENTS
SECTION 4 - HYDRAULIC ADJUSTMENTS
18
PRESSURE
GAUGE 2
TAP 1
06
09 17
TAP 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

VALVE 06 - RELIEF VALVE
ADJUST PRESSURE READING GAUGE ADJUST PRESSURE READING GAUGE

2
VALVE 17 95 +/- 5 kg/cm
2
2 VALVE 06 30 +/- 3 kg/cm 2
PURPOSE: This adjustment sets the maximum PURPOSE: Valve 06 adjusts the low pressure for
pressure for the hydraulic system. It prevents motor the foot pedal and the blade change mode.
overload.
PROCEDURE:
1. Supply hydraulic pressure to gauge 2 by opening
PROCEDURE:
tap 2.
1. Supply hydraulic pressure to gauge 2 by opening
2. Loosen the lock nut on the relief valve 06.
tap 2.
3. Have an assistant activate the clamp by pushing
2. Shut off the supply of hydraulic pressure to the
the foot pedal down.
pressure gauge on the front of the machine by
4. While observing the reading on gauge 2, adjust
closing tap 1. Note the gauge is not shown in the
valve 06 until the pressure indicated is 30 ± 3
illustration above.
kg/cm2.
3. Turn on the 660 cutter.
5. Tighten the lock nut on the relief valve 06.
4. Activate the knife and the clamp by having an
6. Close tap 2.
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/cm2.
7. Tighten the lock nut on valve 17.
8. Close tap 2 and open tap 1.
660P CUTTER
4-2
VALVE 18 - SEQUENCING VALVE
ADJUST PRESSURE READING GAUGE

2
VALVE 18 60 +/- 1 kg/cm 1
2
OPERATOR CLAMP CONTROL 50 +/- 10 kg/cm OPERATOR
PURPOSE: Valve 18 adjusts the clamp pressure.
PROCEDURE:
1. Loosen the lock ring and turn the outside Operator
clamp pressure control fully clockwise. Pressure
2. Activate the knife and the clamp by having Gauge
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/cm2.
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/cm2.
8. Tighten the operator clamp pressure control Lock Knob Operator Clamp
lock ring. Pressure Adjust
Knob
VALVE 09 - SEQUENCING VALVE
PURPOSE: Valve 09 adjusts the return timing Operator Clamp Control

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.
660P CUTTER
4-3
Hydraulic Circuit Diagram
660P CUTTER
4-4
SECTION 5
ELECTRICAL DESCRIPTION
&
ADJUSTMENTS
SECTION 5 - ELECTRICAL & ELECTRICAL ADJUSTMENTS
START UP AND SHUT DOWN PROCEDURE AUTOMATIC SHUT OFF

The paper cutter is designed to calibrate itself each The paper cutter moves the backgauge to the rear
time it is turned on (It also can automatically calibrate point and shuts itself off after being idle for 10
after a given number of cutting cycles - see item minutes.
number 4).
As outlined in the “START UP AND SHUT DOWN
Do not turn off the cutter’s power with the backgauge PROCEDURE,” it is necessary to move the
at the home position. backgauge forward and perform the power on
calibration procedure.
If the shut down procedure is not used cutting
accuracy is not guaranteed. Cutting accuracy is not guaranteed if the shut
down/automatic calibration procedure is not
SHUT DOWN PROCEDURE used.
ACTION RESULT
1. Press the The backgauge
<FAST FWD> button will move towards the
operator
2. Release the The backgauge will

<FAST FWD> button stop moving.
backgauge is
at least 2 inches
from the back of the
cutting table
3. Turn the power off The cutter will shut

down.
660P CUTTER
5-2
SECTION 5 - ELECTRICAL DESCRIPTION & ADJUSTMENTS
SETUP FOR PROGRAMMATIC MARK II

5. Press <END> The first two options
The 660P paper cutter is controlled by the will be indicated at the
Programmatic Mark II controller. Use the following bottom of the display.
procedure to make changes or verify settings in the See Figure 1
Programmatic Mark II controller.
6. Press the <NEXT> key to advance to the desired
option. Enter the desired value.
Note: the Programmatic Mark II controller is used in
several different model paper cutters and therefore THE NEXT STEPS ARE VERY IMPORTANT. YOU
has an option (Option 8) that can be changed to MUST PERFORM THE FOLLOWING TO MAKE
accommodate models other than the 660P. THE DESIRED CHANGES.
7. Advance through the menu, changing any

IMPORTANT KEYS AND THEIR FUNCTIONS options as necessary, until the program number
reaches PROG: 1.
KEY FUNCTION
<PROG> Use to select the set up mode 8. Turn off the power.
<0> thru <9> Use to change values
<END> Used as an enter key
<NEXT> Moves to the next field
<LAST> Moves to the previous field Maximum Program
Power OFF Memorizes a setting cutting distance Number
PROCEDURE
C: 26” 496 PROG: 0
ACTION RESULT
1. Turn the power The backgauge will 1: 674.9 mm 2: 050.0 mm
switch to the move all the way back.
START position During this time the
display will indicate
“BACK TO ORG Option 1 Option 2
WAITING.....”
2. Press <PROG> The cursor will blink

indicating where to Figure 1 - Sample Display
enter the choice for a 660P Programmable Cutter
program number
3. Enter the number The display changes to

<0> for the option “PASSWORD X X X X”
menu
4. Enter the password The display will indicate

by pressing <1>,<2>, the digits as they are
<3>, and <4> entered
660P CUTTER
5-3
ITEM NORMAL
NUMBER FUNCTION SETTING NOTES
1 Rear calibration point 674.9mm* * Perform procedure for exact results
2 Backgauge pushout 050.0mm Distance the backguage pushes the paper

distance towards the operator after a cut.
3 Front safety size 050.0mm 020.0 mm with the false clamp installed.
4 Auto calibrate 0000~0099 Determines number of cutting cycles before

automatic calibration occurs.
Note: 0000 = Off
5 Distance before 10mm If the distance is too short the cut accuracy may
backgauge motor slows be poor. If the distance is too long the size
during cut size change. change will take longer.
6 Distance from the rear 000.1mm This value may be increased to 000.2mm if there
calibration point before the is play between the worm gear and the
backgauge break is backgauge.
applied
7 Backgauge reverse 1.4 This is the distance the backgauge moves in

direction fine stop adjust reverse before proceding slowly to the cut point.
Note: A setting of 1.0 = 16mm.
8 Display Units 1111 This setting determines which model cutter AND
the unit of measurement (inches or millimeters).
1111 for model 433 with display in inches
0011 for model 433 with display in millimeters
Table 1 - Option Settings
660P CUTTER
5-4
SETTING INSTRUCTIONS FOR ITEM 1 cording to the above guidelines.

REAR CALIBRATION POINT
6. Repeatedly push the <NEXT> key until “PROG:1”
This procedure should be performed if there is an is displayed.
error in the cutting distance measurement.
7. Turn the 660 cutter power off.
This setting describes the distance from the cutting
line to the furthest distance possible from the cutting 8. Wait 5 seconds and turn the power back on.
line. It is referred to as the rear calibration point. Repeat this procedure until there is no difference
in the lengths of the op side and non op side
For reference purposes: pieces of paper.
Using a known size piece of paper, the piece of
paper closest to the operator is the operator side
piece and the piece of paper towards the rear of
the machine is the non-operator side piece.
PROCEDURE
1. Write “op side” on the operator side of the sample

paper and “non op side” on the non operator side
of the sample paper. C: 26” 496 PROG: 0
2. Cut the sample paper in half. 1: 674.9 mm 2: 050.0 mm
For example: If the sample paper is 17 inches

and it is cut lengthwise, the cutting distance must
be set to 08.50 inches. Option 1
Add or subtract from this value
3. Carefully align the pieces together and determine
the difference in millimeters, if any, in their lengths.
Figure 2 - Back Point Adjustment
If the “op side” is longer you need to decrease the
rear point value.
If the “op side” is shorter you need to increase the

rear point value.
4. Access the rear point adjustment (by default the

first item is rear calibration point). See detailed
instructions in this section.
5. Divide the distance measured in step 3 in half.

Increase or decrease the value of option 1 ac
660P CUTTER
5-5
TERMINAL LED NAME PORT DESCRIPTION STATUS
3 400 KEY Input Key switch NO

12 401 PB-1 Input Cut pushbutton 1 NO
13 402 PB-2 Input Cut pushbutton 2 NO
14 403 LS-D Input Knife down limit switch NO
15 404 LS-U Input Clamp top limit switch NC
16 405 LS-A Input Photoelectric protection circuit NC
17 406 T1 Input Knife adjustment timer NO
18 407 PB-K Input Knife change switch NC
20 410 LS-C Input Foot pedal switch NO
23 411 NC-1 Input Mark-II control NC
25 412 LS-E Input Backgauge rear safety switch NC
25 413 LS-E Input Backgauge rear safety switch NC
6 430 D Output Knife down relay N/A
U 431 U Output Knife up relay N/A
9 432 T1 Output Knife adjustment timer N/A
P 433 P Output Clutch N/A
19 434 BZ Output Buzzer N/A
4 435 M Output Main motor control N/A
C 436 C Output Clamp pressure relay for foot N/A
27 & 2A 437 TR1 Output Transformer for Mark-II N/A
Table 2 - PLC Inputs and Outputs
660P CUTTER
5-6
KEY
ABBREVIATION DESCRIPTION
O.L. Main motor thermal overload relay
Key Main key switch
PB-1 Cut push button 1
PB-2 Cut push button 2
PB-K Knife change switch
LS-D Knife bottom position switch
LS-U Clamp pressure top position switch
LS-C Foot pedal switch
LS-E Backgauge rear safety switch
NC-1 Signal from MKII control
A Photo electric control (optional)
D Knife down relay
U Knife up relay
C Clamp pressure relay for the foot pedal
M Main motor control
T1 Knife adjustment timer
ML Motor pilot light
CL Cutting line light
TR Main transformer
RF Clutch rectifier circuit
BZ Buzzer
P Main motor clutch
Table 3 - Main Electrical Diagram Key
660P CUTTER
5-7
Figure 3a - Electrical Diagram for PLC
660P CUTTER
5 - 8
KEY
ABBREVIATION DESCRIPTION
LS-D Knife bottom position switch
LS-R Micro adjustment switch
LS-S Rear point switch

P1 Backgauge brake
R1 Backgauge on/off relay
R2 Backgauge forward/reverse relay
R3 Backgauge fast/slow relay
SB Backgauge slow speed adjustment
SSR Slow start relay
TR1 MKII power transformer
5-9
Figure 3b - Electrical Diagram for Programmatic MKII and Backgauge Motor Circuit
660P CUTTER
APENDIX A
600P Cutter Quality Control Check List

Duplo USA Corporation

Quality Control Check List
660 Cutter
Serial Number: _______________________________________ Date: _________________
Technician Name: _____________________________________ Dealer: ________________
Company: ___________________________________________ Phone: ________________
Address:_____________________________________________ City:__________________
State: _____________________ Zip:_____________________ Fax: __________________
Tech Check Point Comments:

OK
1. Check record AC Power VAC.
2. Check control panel by
pressing the buttons.
3. Check back gauge clutch by
pushing the adjustment knob in
the front of the machine.
4. Input a size and press run to
see if C# and 1# matches.
5. Testing balance for the square
ness of the back gauge.
6. Check the vertical square ness
of back table.
7. Check from panel pressure
gauge for 50 to 60 PSI during a
cut.
8. Check the maximum cutting
ability.
9. Program and perform a 10” and
a 5” cut.
10. Check foot pedal operation.
11. Check knife cutting line light
is on.
12. Perform a overall visual
inspection for appearance.
13. Check and write down 1) 5)
program 0” parameters on the 2) 6)
right side of this sheet. 3) 7)
4) 8)
Operator sign off / acknowledgement:______________________________________________
Quality control performed by: ____________________________________________________
Comments
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
Installation Check List
1) Check voltage on the machine after electrical wiring is done by checking the T and L on the
terminal board to see if it is between 208v -232v, if not you will have to install a buck booster
transformer
2) Turn on the machine and check the control panel by pressing of any of the buttons and to see
if the LED display is ok
3) Check the clutch by pushing the fine adjustment knob on the front of the machine, by pushing
it in and out this is to check to see if the gap on the clutch sounds right if not please refer to the
instructions later in this manual.
4) Input a size into the control panel press the run button verify if the # C and # I matches,, if so
then you do not have to do a thing . If it does not match, then you have to adjust the low speed
adjuster in the main electrical panel on the bottom of the box (white knob) by turning the knob
very slightly at a time and by pressing the run button till the sizes matches the control panel
5) Put a stack of paper on the right side of the cutter and select a size, then press run, make a cut,
now move the stack to the left side of the cutter make a cut, if there are any shavings, you will
have to adjust the backgauge till you have no more shavings and the backgauge is square. Please
refer to the maintenance manual on page 2.5 to show you how to do this adjustment.
6) Put a full stack of paper into the cutter, make a cut then check it by taking a sheet form the top
and one from bottom and comparing them to see if the paper is cut at a angle. If it is at an angle
you must make an adjustment, instructions are in the later part of this manual.
7) Put a 10" cut into 1# place, then press next, then put a 5" cut into 2# then press next then
press end twice then press the auto button and the machine will go to the first cut, cut some
paper for the 10" cut, then cut the 5" cut and put them together to see if they match, if not, you
must adjust the rear calibration point till it matches both cuts. Instructions are on page 5.5 of the
maintenance manual
8) This is to check for the maximum cutting ability, Place a full stack of heavy paper stock into
the machine and make a cut, if it cut all the way thought then it’s OK, if not, go to the later part
of this manual for more information.
9) Check the pressure gauge on the front of the machine by making a cut. It should be about 50
to 60 p.s.i.
10) Check the foot pedal to see if the clamp comes down and is operational.
11) Check and see if the knife cutting line light is on if not replace it. Instruction are in the latter
part of this manual.
12) Check knife changing switch by turning the switch to the #1 position and pressing the two
yellow button the knife will go down and stay down then turn the switch to #0 and the knife will
go back up if so it is ok, if not go to the maintenance manual on page 4.3, valve adjustment #9
13) Write the program parameters down on paper by pressing program then #0 then pressing the
# 1,2,3,4, buttons, then press end Then go thought # 1 -8 and by pressing next Jill you get to the
end of the parameters press the next or last twice then press reset to return to the main program
14) Now install the two side tables on the machine The instruction are on page 9 & 10.
15) Perform a visual inspection (cover and overall appearance) if all looks good, you may sign
off on the installation / Q.C. form
How To Adjust The Full Maximum Paper Cutting Ability
Take a full stack of heavy paper stock and place it into the cutter and make a cut, if it cuts all the
way thought then you are ok, but if does not cut all the way thought then you have to do the
following:
1) Take the top back cover off
2) Adjust the clamp pressure top position switch, by loosening the allen screw on the long arm
of the switch and moving it more down towards the clamp and do this a little at a time
3) Make a cut every time you adjust the long arm do this till you can cut all the way thought the
stock
How To Adjust The Backgauge Clutch
1) Make sure the power is off to the machine.
2) Take off the long side cover one bolt is under the cover and the other two are on the side of
the fence.
3) Loosen the two nuts on the clutch and loosen the three allen screws.
4) Open the gap on the clutch and place two sheet of 20 lbs. stock one on the top and one on the
bottom.
5) Adjust the gap so that the paper is just touches the gap between the two plates.
6) Tighten the allen screws and the two nuts.
To check if the gap is right, tam on the power to the machine and push in and out the fine
adjustment knob on the front of the machine to hear if there is a clicking sound that is the clutch
engaging and disengaging if it sound right you are done.
Cutting Table Vertical Adjustment
1) Take a full stack of paper and put it into the machine and make a cut, compare the top sheet
with the bottom sheet to see if it is at a angle or if it matches if not go to the next step.
2) Take off the front and bottom back cover.
3) Loosen but do not remove these bolts there are 2 of them that are horizontal bolts in the front,
the other 2 of them are vertical in the back of the machine, these 4 bolts are 19mm.
4) There are 2 smaller vertical bolts under the back of the cutting table, on the left and the right
side These are the ones that change the angle of the cutting table loosen the 2 nuts on the bolts
so you can adjust the bolts.
5) By determining the angle needed to be adjusted by the cut sheet that you have done, lower or
raise the bolts evenly on both sides, by making a cut and adjusting the bolts, till it is vertically
square.
6) Tight all the nuts and bolts and make another cut of a full stack of paper to confirm the
adjustment has not moved. If there is no change, you are finished. If so you have to re-start from
1) until it is square.
How To Replace The Knife Cutting Line Light
1) Take top front cover off
2) Loosen the bolt and pull the light away from the mounting bracket
3) Disconnect the male from the female connector and remove the 2 phillip screws from the
mounting bracket and take out the old light
4) Put the new light in by connecting the male to the female connector and putting the 2 phillip's
screw back into the mounting bracket
5) Put the mounting bracket bolt back on the bar with the bracket and tighten the bolt
6) Alien the light so it is between the knife blade and the clamp so that the line can be seen on
the cutting stick
Model 660 Trouble Shooting Guide
(Controlling Switches)
Code Symptom Cause
Please check top switch 1) Machine will not let you cut. Ls-u clamp
and machine is buzzing 2) Bad continuity on switch. pressure top
all the time. 3) Check switch wiring. switch is bad.
Encoder error 1) In a program and making a Encoder is bad.

Please check encoder. cut and error comes up.
2) Press run button and error
comes up.
660 is costantly buzzing
Symtom Cause Correction

660 is constantly buzzing This occurs when the machine 1. Change the Knife
has done 3000 cycle and it is 2. If the knife has recently been
prompting a knife change changed. Turn the knife change switch
form left to right.Depress both yellow
cut button ,the knife will come down to
the bottom position.Turn the knife
change switch form right to left, the
knife will return to the top position
Model 660 Trouble Shooting Guide
(Mark-II Programmatic Control)
Symptom Possible Cause / Correction
(a) Mark-II can not start 1. The clamp doesn’t to top position ,LS-E doesn’t work
(wires SS,UL )
2. The backgauge rear safety switch (LS-E) is broken
(wires M, 25 )
3. The fuse is blown ( fuse 3 )
4. Mark –II programmatic control is out of order
(b) Mark-II starts 1. Backgauge locking handle does not reset

completely but (wire SS ,RL )
can not operate. 2. The clamp doesn’t return to top position ,
Mark-II can not run (wires SS, RL).
(c) Backgauge moves 1. Backgauge low speed adjuster is broken (SB)

in high speed, but
low speed can’t be
engage.
(d) Encoder problems. 1. Cut position is incorrect.

2. After calibration the rear position ,backgauge move forward in
high speed, then locked.
3. Backgauge moves forward a section in high speed , then
locked
4. Sunray 2 error will come on
5. If encoder is bad ,if you have more than 1’’ on your cut
size ,check the encoder.
(e) Backgauge motor 1. When R1,R2 & R3 are activated, sparks are shooting
Control is broken. out of the contacts, or the contacts are melted, the SSR relay is
broken, replace the SSR so it will kill the sparking on the
contacts.
(f) Power is ON, cutting 1. Key switch is broken (wires M,3)

light glows, but can’t 2. PLC has no power, PLC doesn’ t work
start the motor.
(g) When starting the 1. The motor thermal overload is overloaded (OL)
motor, the run indicator
light glows, but motor
can’t run.
Symptom Possible Cause / Correction
(h) Clutch problem 1. Large noise : the gap of clutch is too small
Correction : readjust the gap
2.The power to the clutch is not enough
The gap on the clutch is too big
The voltage is to low
Correction : is to install in series a Condenser (220uf ,50v) on
both sides of the terminal (wires +,- )
(i) Knife is coming 1. Lubrication oil is not enough

down too slow. 2.Clutch is out of order
3.Hydraulic pressure problems
(j) Control panel shows: 1) Backgauge moving to slowly so you are unable to input any
Back to Org. numbers in to the control panel.
Wait…
2) Adjust the slow speed pot adjustment in the main electrical

panel on the inside of the machine, on the bottom (white knob) to
speed up the backgauge and, so that the display matches the C#
and the 1# correctly.
Model 660
Trouble Shooting Guide
( Controlling Switches )
Codes Symptom Cause

Ls-U . clamp pressure 1. When after making a cut ,the knife goes up, Ls-u does not work
top position switch buzzer beeps for one second ,then stop
P.s. The same as the problem as cutting
a large pile of sheet
2. Turn on the power ,buzzer beeps ,then you Ls-u has no action
start the motor buzzer beeps once ,but
you can’t make any cuts ,and the Mark-ll
programmatic will not run
Ls-D. Knife bottom 1. When depressing PB-1& PB-2 cut button Ls-D doesn’t reset
position switch ,buzzer beeps, but machine doesn’t make a
any cuts
2. If a deep cut is made ,buzzer will beep until both Ls-D doesn’t work ,or
cut button are released , then knife goes up to knife changing switch
the top and the motor will shut off automatically. is wrong
T1.Knife adjustment 1. The knife cannot be engaged ( go down ) Bad contacts on D& 8
timer 2. When making a deep cut ,buzzer will beep T1 has no action
until both cut button are released ,then
knife goes up to the top and the motor
will shut off automatically
Pb-K. Knife change 1.The knife comes down and stop at the bottom Bad contacts M& 18
,but will not return to the top position Bad contacts 2&21
Ls-C Foot pedal 1. Turn on the power,but you can not start the Ls-C is locked
motor ,buzzer will beep for 3 seconds and
then stop . At this time , the foot pedal
is not function automatically ,then you
can start the motor
Nc1. From Mark-ll 1. The knife can not make a cut Bad contacts M&23
2.When knife comes down and occasionally
holds back ,and you need to re-press both
cut buttons
Model 660p
Machine wiring for switches and the timer

Ls-U upper limit switch
Switch position N/o O –3 4- O N/o

Wiring mark UL SS
__________________________________
N/c O-1 2- O N/c

M 15
Ls-D lower limit switch

N/o O-3 4-O N/o
14 M
__________________________________
N/c O-1 2- O N/c

SS DL
Backgauge limit switch
Common N/o N/c

25 no connection M long arm switch
__________________________________
Common N/o N/c

SS no connection SL short arm switch
Foot peddle switch
Left switch Right switch
N/c N/o Common Common N/o N/c
O O O O O O
No connection 6 8 M 20 no connection
T1 . Knife adjustment timer Pb-K Knife change switch NC1. From Mark-ll
wirers M & 17 wires M & 18 wires M & 23
D& 8 2 & 21
Model 660P
Trouble Shooting Guide
Sympton Possible Cause Correction
Knife or clamp will not 1) Bad Ls-u top clamp switch Replace the
go down when foot or Ls-d down switch switch
pedal is pressed or ( check note )
when the two yellow
button is pressed 2) T1 is not working right Replace T1
3) The knife down and up Replace

relay is not working relay
in the down mode on the hydraulics
#8
Note : This is how to check the top Ls-u and bottom Ls-d switches to see if
they are ok
1) Remove back top cover and find the switch Ls-u ,next take the
allen screw off one side of the Ls-u switch and tilt it to the side
2) Remove the side cover where the Ls-d switch ,so you may touch
the switch when you have to
3) Now have someone hold the arm of the Ls-u switch in the up
position
4) Turn on the power to the machine
5) Now press the two yellow buttons and release the arm of the Ls-u
switch ,then touch the Ls-d arm ,next then move the arm of the
Ls-u into the up position
6) Turn off the power to the machine and put all the parts back in
there place
Comment : If the U relay works on hydraulics system then the switches are
are working right ,also you can check the inputs and outputs
signal on your PLC unit
Wiring for the 660P

T1 Knife adjustment timer
The T1 timer is a eight pin potentiometer to witch has two sides to it and
has two pins for the power
-----------------------------------------------------------------------------------------
power inputs
• o
2 7
---------------------------------------------------------------------
Right side of switch
n/c n/c
5 8
n/o n/o
6 8
---------------------------------------------------------------------
Left side of switch
n /c n/c
1 4
n/o n/o
1 3
-----------------------------------------------------------------------------------------
Explanation : This is a three pin output connector ,when the switch is

activity the switch goes for normally close to normally open
Wiring for the new switch on the top of the knife
Knife top position Clamp top position

switch switch
|______________| N/c |____________________| N/c |_____________ |
| | | | | |
S S AA UL
The SS,AA,and UL are all wiring points to the terminal, and on the switch.
Explanation: New switch on the top of the Knife.

The knife top position switch is a series connection with the clamp top position
switch, it is a new safety device for the Mark- II Programmatic signal, when the knife
does not go up to the top position, because of it, the backgauge will not move to the next
size.
NOTE:
New Light Safety Curtain for 660 Cutter

The new light safety curtain will not work the older machines, because they do not have a AC 24 V power
wire fitted, if you would like to mount the new light safety curtain on the older machines you need to connect a 24
V wire form the transformer, and also you would have to do some modifation to the side tables, in order to mount
the light safety curtain.
The light safety curtain will work on machine above the serial number 0104034, and will not work below
that serial number without doing modifation.
Important Note: Use discretion when ordering this and any other parts or options. Check the serial number
of the machine or machines and compare them to the implementation number before ordering this option.
Fax all parts orders to the Parts Department at (949) 752-7766. If you require further information or
assistance, contact Duplo U.S.A. Technical Department, Graphic Arts Division at (949) 752-8222.

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Copyright © 2000 Duplo USA Corporation

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

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

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

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

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

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

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

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

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

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

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

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

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

* Specifications subject to change without notice

SECTION 2 - MAINTENANCE & ADJUSTMENTS

There are several locations that require periodic oil

Signs that the cutting blade requires sharpening:

SECTION 2 - MAINTENANCE & ADJUSTMENTS

WARNING 11. Remove the two vertically oriented bolts holding

SECTION 2 - MAINTENANCE & ADJUSTMENTS

CUTTING TABLE SQUARENESS

TESTING FOR CUTTING TABLE SQUARENESS

b) Place a small block under the clamp. Lower

CUTTING TABLE ALIGNMENT

2. Remove the front and rear covers (four Allen

Figure 2 - Cutting Table Bolts

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

5. Adjust the table adjusting bolt until the table is

6. Test for squareness. When satisfactory, lock the

SECTION 2 - MAINTENANCE & ADJUSTMENTS

3. Turn the remaining sheets over and push them