Morgan Documaster Pro User manual

70-174 Issue 4 FEBRUARY 2013
Documaster Pro (CB/UL)
SERVICE MANUAL
Document Creasing & Automatic
Morgana Systems Limited United Kingdom www.morgana.co.uk Telephone: ( 01908 ) 608888 Facsimile: ( 01908 ) 692399
Booklet Making Machine

Page 2
INTRODUCTION
CREASING / BOOKLET MAKING
MORGANA DOCUMASTER PRO
i ..........Introduction
ii .........Fasteners
The purpose of this manual is to explain the procedure for dis-
mantling and re-assembly of the major assemblies on the Morgana
Documaster PRO machine.
All the engineering adjustments are shown at the end of each
relevant section.
Operator's adjustments and routine maintenance are explained in
the appropriate operators manual which should always be used in
conjunction with this manual.
It is always a good idea to have a copy of the machines illustrated
parts manual available when servicing, as its illustrations provide an
invaluable reference to the construction of the individual assemblies
used to build the machine.
All threaded fasteners are isometric & all nuts are isometric hexagon.
All screws are hardened high tensile steel.
Cap head, Button head, Socket countersunk, Shoulder bolts and
Grubscrews have internal hexagon drives which require isometric
hexagon wrenches (allen keys). Ball drivers may be used, but care
should be taken particularly when releasing screws for dismantling
to avoid breaking the driver as they cannot cope with full tightening
torques.
NOTE.........Do not substitute fasteners with low grade alternatives
which may fail or become irremovable.

Page 3
SYSTEM
Pan head and Cross-head countersunk screws all have metric Taptite threads and
Pozi-drive recesses. Use No.2 point Pozidriv or Supadriv drivers for all screws M4
& above, and No.1 point drivers for M3 & below.
WARNING
Warning
This machine is heavy care should be taken
when handling
iii ........Identification
iv ........New Machine Preparation
For general identification of areas of the machines, the
following terms are used:-
Operator side (control consul facing)
Rear of machine (opposite to control consul)
Delivery end (to the left of the operator side)
Feeder end ( on your right )
Remove all packaging materials
All metal parts, including the folding rollers have a protective
coating
And any excess should be removed.
Connect the power cable to the mains supply. The machine
requires 230V 50Hz 10 Amps or 115 60Hz 15 Amps.
Fit the delivery to the machines together as described later in this
manual.
Turn the rollers by hand to ensure they rotate freely.
Switch on the machine and check that all functions operate. Set up
the machine and check that the machine feeds correctly.
WORK SHOULD BE CARRIED OUT BY A TRAINED AND COMPETENT
ENGINEER AND ALL SAFETY PROCEDURES SHOULD BE ADHERED
TO.
SWITCH OFF MAINS POWER BEFORE COMMENCING.
DO NOT USE PHILLIPS DRIVERS - THESE WILL DAMAGE THE
SCREWS & MAY SLIP, CAUSING DAMAGE OR INJURY.
DocuMaster Pro

Page 4 CREASING / BOOKLET MAKING
INDEX
Introduction
Section 1
Section 2
Section 3
Section 4
Section 5
Section 6
Section 7
Section 8
Section 9
Section 10
Section 11
………………………………………………………………….....……..PAGE
¡ Introduction ................................................................. 2
¡¡ Fasteners .................................................................... 2
¡¡¡ Identification ................................................................ 3
iv New Machine Preparation ............................................ 3
V Index............................................................................4/5
Vi Key to Creaser Unit........................................................6
…… Covers………….…....................................................................
Creaser Covers............................................................. 7
Gatherings Station Covers............................................ 8
…… Vacuum Drum…………………………………………………….
Belt Removal/Replacement........................................9/10
…….Butterfly Valve
Removal/Replacement.................................................12
……Main Mechanism - Creaser Unit................................................
Removal of Unit..........................................................14/15
Removal /Replacement Stepper Drive Belt / Pulleys......16
…….Infeed Roller Removal/Replacement - Creaser……………………...17
…….Drive Hub - Replace Rubber Torsion Bush (shock absorber)..........18
…….Drive Link Refurbishment…….…………………………………...........19
…….Width Drive Mechanism…….…………………………….......……......20
…….Gathering Station Removal/refitting.…………………….......……......21
…...Gathering Station Timing Belts Removal/refitting.…….......……......22
……Creaser Electrics…..………….…………………………….......……...
Removal/Refitting PCBs. ......................................................23
Removal/Replacement Controller PCB....................................24
Processor PCB Replacement .................................................25
Relay PCB Replacement ........................................................25
Removal of USB Flash Drive...................................................26
Removal/Replacement Stepper Drive PCB ............................27
Removal/Replacement Small Stepper Drive PCBs ................27
....

Page 5
SYSTEM
Section 12
Section 13
Section 14
Section 15
Section 16
Section 17
Section 18
Section 19
Section 20
Section 21
Section 22
…….Gathering Station Electrics….…………………………….......……PAGE
Removal/Refitting PCBs. .....................................................28
Replacement Interface PCB....................................................28
Removal/Replacement Stepper Drive PCB ............................28
Removal/Replacement Small Stepper Drive PCBs ................28
…..Optical Sensors…….…………………………………………................
Creaser - Cleaning and Setting....................................... 29
….Machine Installation............................................................................
Machine Installation....................................................31
Software upgrade Watkiss bookletmaker....................31
….Machine Set-up Prior to Calibration..................................................32
….Replacing Touch Screen Assembly…………………………..............33
…Calibration…….…………………………………………...............
Calibration of crease position ......................................34
Width Trim ...................................................................34
Calibration of Gathering Station paper guides............35
Switching from Watkiss to Nagel.................................36
Setting the Measurement System METRIC to INCH...36
Zero Total Count .........................................................36
….Trouble Shooting…………………………………………………
Error Messages.........................................................37
Camera and Double Detect.......................................37
Creasing Unit........................................................38/41
Machine Width Positioning.......................................41
Gathering Station..................................................47/48
…Creaser Circuit Diagrams………..………….……………….......…
UK - Wiring Diagram................................................49
Control PCB Connection Diagram............................50
…Gathering Station Circuit Diagrams………..………….…………
UK - Wiring Diagram...............................................51
Control PCB Connection Diagram...........................52
….Fuse Positions & Ratings ............…………………………..............53
…Image Recognition Camera………..……………….......…
Camera Replacement...........................................54/56
....
DocuMaster Pro

Page 6 CREASING / BOOKLET MAKING
THE CREASING UNIT
Key to photograph below
1 Roller tilt handle
2 Stacker assembly
3 Suction slot knob
4 The control panel 16 Gathering Station
5 Air distribution knob
7 Adjustable side lay 13 Vacuum Bleed Knob
8 Back stop 14 Touch Screen
9 Fixed side lay 15 Anti-Static Unit
10 Roller tilt knob
11 Paper Gate
6 Air separation knob 12 Exit Guard
DocuMaster Pro
8
7
4
1331016

Page 7
SYSTEM
SECTION 1
1.1
1.2
1.3
1.4
Creaser Covers:
The Front Cover
The Service Panel (Rear Panel)
The Creaser Mechanism Covers
The Loading Table.
The compressor cover which is situated below the control panel is secured by 16 off M4
taptite screws and is located by three tongues protruding into the main frame.
Removal of this cover provides access to the compressor & the crease mechanism and
the Camera cable termination.
To remove this cover, remove all screws and twist forwards to clear emergency stop button
and mains socket, pull out to release the tongues.
The Service Panel is at the rear of the machine and is secured by seven screws, three on
the top.
Removal of this panel allows access to the suction pipework and the Electric Control
System assembly.
The creaser mechanism is situated in the middle of the machine and is covered by a fixed
and a hinged guard.
To remove these guards just remove the four screws (M4 x 8 long) beneath the entry
guard. Pull off the rubber handle from the tilt lever, the entry guard can now be lifted
upwards and removed.
Removal of the loading table is as follows:-
Remove all eleven countersunk screws from the feed bed. Loosen the sidelay screws and
bring the sidelay assembly towards the operator side of the machine. Then lift out the
loading table towards the rear of the machine, passing over the fixed lay of the feed bed.
if
fitted,
To remove this panel, first remove the Touchscreen, (access through two holes in the
cover) loosen all screws, lift up the panel and twist outward to unhook the keyhole
locations on the opposite side to the screw fittings.
The Loading table is the stainless steel top on which the work is loaded.
DocuMaster Pro

Page 8 CREASING / BOOKLET MAKING
SECTION 1
1.8
Gathering Station Covers:
The Side Covers
The Rear Door
The Rear Panel
1.5
1.6
1.7
The side covers of the gathering station are each fixed with 5 off M4 taptite screws (3 off on
top).
The Op. side covers the drive pulley and friction clutch.
The Lay side covers the gathering station PCB and guide pulleys.
To remove covers, remove all screws and lift clear of the machine. NOTE: The lay side cover
has a key hole slot that secures the machine interface cable. This can be released when
removing cover.
Reassembly is the reverse order ensuring that the interface cover grommet is secured back
into the key hole slot.
The rear door is secured by 3 off tatpite screws. Removal of these screws will allow the door to
pivot open for access to the Hamlin Switch, Pot assembly and the mains power terminals.
The rear panel is secured with 12 off taptite screws and provides access to the electrical panel
assembly.
To remove, first open the rear door by unscrewing the 3 off fixing screws then continue to
remove the remaining 9 off taptite screws. The panel can then be lowered from the gathering
station. Reassembly is the reverse.
switched on at
The Interface Cover Assembly
The Interface Cover is situated between the creaser unit and the stapling unit and covers the
Alignment Channel which connects the Stapling and Creasing parts of the machine.
To remove this cover , two securing screws can be removed from the top flange and the cover
can be lifted clear giving access to the fixing screw through the channel.
Reassembly is reverse to the above, ensure the mains is plugged in and the
stapling unit, and the interface cable is attached at the creaser end. Care should be taken not
to damage these cables.

Page 9
SYSTEM
SECTION 2
VACUUM DRUM TIMING BELT REMOVAL / REPLACEMENT.
2.1 Remove the Feed Bed, Moving Sidelay, Papergate Assembly, Ball Holder, Support
Bracket and Double Sheet Detector Mounting Bracket. (See Fig. 2.1 below).
2.2 Remove the two screws that secure the Butterfly Valve. (The Butterfly Valve is located
2.3 Remove the two screws that secure the Vacuum Drum Mounting Block. The Vacuum
Drum Mounting Block can now be slid towards the back of the machine, (to
disengage it from the Vacuum Drum), and it can now be removed.
2.4 Remove the Sensor, the Timing Belt can now be removed.
2.5 Replace in reverse order, making sure that the two ‘O’ rings are in the Vacuum Drum
Mounting Block.
on the underside of the feed bed, towards the back of the machine.
Vacuum Drum
Mounting Block
Papergate
Assembly
Ball
Holder
Support
Bracket
Sensor
Vacuum
Drum
Timing
Belt
FIG.2.1
DocuMaster Pro

Page 10 CREASING / BOOKLET MAKING
VACUUM DRUM FEED BELT REMOVAL / REPLACEMENT.
2.7 Remove the M5 Socket Screw. (See FIG.2.2 below).
2.8 Remove the 3 screws securing the Center Support Plate (Posi Head Screw
in the side of the feed frame and 2 Cap Head Screws, from under the feed frame.
DO NOT adjust or remove the red bolt, as this is factory set.
2.9 Carefully slide the Center Support Plate towards the front of the machine.
Be careful when doing this as two bearings and shims can fall out.
2.10 The Feed Belt can now be removed..
2.11 Replace in reverse order, again be careful of bearings and shims.
When fitting the Center Support Plate, make sure it is up against red bolt and washer.
2.6 Remove the Feed Bed and the Moving Sidelay.
FIG.2.2
M5 Socket
Screw
Bearings
and Shims
Center
Support
Plate
Feed Belt

Page 11
SYSTEM
BLANK
PAGE
DocuMaster Pro

Page 12 CREASING / BOOKLET MAKING
SECTION 3
Removal of Butterfly Valve Assembly.
The Butterfly Valve assembly is located on the underside of the feed bed, towards the
back of the machine.
3.1 Remove the two pipe mounting clip plates (ITEM 5 on page 13) so that the hoses can
be detached from the valve.
3.2 Remove the two screws that secure the valve to the underside of the feed bed.
When refitting the valve ensure that the ends of the hoses are clear of nylon fibres and that
the ‘O’ ring is in place.
NOTE.

SYSTEM Page 13
4 Posns.
11
2 Posns.
13
4
9
8
7
2
10
14
2 Posns.
11
2 Posns.
5
6
4 Posns.
12
3
1
Magnet Polarity
Orientation
is IMPORTANT.
Sensor Orientation Nylon Grub Screw
(ITEM 14)
Flat Face of Sensor
2. Magnet Polarity Orientation is IMPORTANT.
1. Items 7 Should Be Secured Into Item 4 using a
Suitable High Strength Adhesive.
NOTES.
BUTTERFLY VALVE ASSEMBLY (175-28-01)
ITEM NO. PART NUMBER QTY. Description
11
2175-164-01 Valve Block Tube - Stepper
3
173-65-01
1
Valve Motor & Lead Assembly
175-176-01
1
4
2Pipe Mounting Clip
5
175-166-01 Solid Butterfly
1
6
401-02-040-008
Dowel Pin Ø3 x 12 Lg.
7601-168 2
81
602-178
175-177-01 Upper Valve Spacer
91
1
10
11
12
603-108
6Screw - Pan Pozi Taptite - M4 x 8 Lg.
404-01-030-008 4Screw - Socket Countersunk Hd - M3 x 8 Lg.
13
173-67-01
409-01-030-008 2Screw - Skt set - Flat Pt. - M3 x 8 Lg.
175-165-01
1
Valve Mounting Plate
Magnet - Ø3 x 3 Long
Bearing - Iglidur Plain Ø3 X Ø5 x 4 Lg.
Lead - Valve Sensor
14 416-01-060-008 1Grub Screw - Slotted Nylon M6 x 8 Lg.
DocuMaster Pro

Page 14 CREASING / BOOKLET MAKING
SECTION 4
MAIN CREASER MECHANISM
REMOVAL OF UNIT:
4.1 First access should be gained by removing the top input and output guards
()
4.2 Remove guard micro switch by removing two screws taking care not to drop them.
4.3 Remove the compressor cover and cut and remove cable ties from cable mountings,
retaining wiring loom.
Ensure that the mains is unplugged.
4.4 From the rear of the machine, remove two M8 button socket screws with their
washers and lift out the spacer bar.
4.5 Remove the ’unlock’ knob from the front of the machine.
4.6 Remove the polycord drive belt from the suction drum.
4.7 The unit can be lifted by two people vertically out of the main frame with care.
One person should be guiding the wiring and plugs to ensure they do not get
trapped during the lifting.
See Section 1

Page 15
SYSTEM
4.8 For working, place the unit on a solid and clear bench ensuring no wires are trapped
beneath the metal side plates.
4.9 Assemble loosely around the green drive belt.
4.10 Replace the unit ensuring the wiring harness is threaded as it was removed
4.11 Attach the belt to the drive shaft.
4.12 Fit the tilt lever to the inside front frame with the bottom button head and screw
in tilt knob.
4.13 Slide rear spacer bar down in position (see below). Fix the bottom screw in and
align the top screw and fit loosely. Replace cable ties to mountings.Align the
roller set square with the fixed lay edge while the front tilt lever is in the centre
position. (Use the rear slots to adjust the square) Tighten the screws and replace
the top covers.
Replacement is as follows.
pulley the
DocuMaster Pro

Page 16 CREASING / BOOKLET MAKING
REMOVAL/REPLACEMENT STEPPER DRIVE BELT/PULLEYS
4.14 Loosen the adjuster nut from the inside unit and slide the belt off.
4.15 Loosen the securing socket set screws in the drive pulley on the roller.
( there is one screw located in a hole in the shaft)
4.16 Slide the pulley from the shaft and remove the belt. See below.
4.17 Refitting the belt is a reverse procedure. To tighten the belt, first adjust the drive
motor down to allow the ‘feel’ of the belt tighteness; then re-adjust the motor / gear mesh to
allow minimum backlash.
NOTE

Page 17
SYSTEM
SECTION 5
REMOVAL/REPLACEMENT OF INPUT ROLLER
5.1 With the unit on a bench.
5.2 Remove the drive belt and pulley from the roller to be removed.
(See SECTION 4)
5.3 Remove the three M4 posi-head taptite screws from around the bearing hole
in the side plate (Drive belt side) to allow easy access to the bearing retaining
rings. Remove rings.
5.4 Slide the roller out and remove the bearing from the shaft drive belt side.
The roller can be turned sideways to allow removal.
Note the position of the spring washers.
5.5 Replace the roller in the reverse manner.
WORKING ON THE DRIVE BELT SIDE:
DocuMaster Pro

Page 18 CREASING / BOOKLET MAKING
SECTION 6
DRIVE HUB:- REPLACE RUBBER TORSION BUSH (SHOCK
ABSORBER).
6.1 Loosen grub screws in one half of hub.
6.2 Slide hub outward & remove rubber.
6.3 Replace in reverse order.
Rubber Torsion Bush

Page 19
SYSTEM
SECTION 7
DRIVE LINK REFURBISHMENT
7.1 Remove the drip tray by removing the four securing screws fixed to the tie bars.
7.2 Remove both tie bars and drip tray.
7.3 Remove the micro switch assembly to gain access to the rear drive link.
7.4 Using a short dumpy posi drive screwdriver, unscrew the three screws from the side
of the link plate. Slide the side off (‘O’ Rings should be maintained in position).
The plastic drive link can be removed by sliding it forward.
7.5 Replace the drive link and outer plate.
7.6 Re-assemble in reverse order.
Micro Switch AssemblyLink Plate
DocuMaster Pro

Page 20 CREASING / BOOKLET MAKING
SECTION 8
WIDTH DRIVE MECHANISM
The width drive mechanism is situated beneath the bottom plinth of the creasing unit. This
mechanism drives the unit sideways via a rack and pinion to position the fixed sidelay of the
creasing unit with the central guides of the gathering station. The position is controlled by a
rack driving a potentiometer, with the electronic program calculating the final position.
For all work carried out on this assembly the following procedures must be carried out first.
Disconnect from the Mains.
Remove the interface cable and power lead, then unscrew the shoulder bolt from the
alignment channel.
Move the creasing unit clear of any obstacles and with two people carefully up end the
machine and lay on its Infeed end face.
With the unit on its back (see below) the drive motor is accessible.
Loosen the four nuts which secure the motor mounting plate, (this enables the pinion to clear
the rack when pivoted away) remove the two button head screws attaching the axle to the
frame and pivot the wheel base down and away to give access to the motor.
Remove the motor and mounting plate, replace motor and ensure the wires are firmly
reattached to the frame as previously fitted, setting the Link Tube central whilst engaging the
rack.
Unplug the pot lead and cut any cable ties, remove the plastic gear from the spindle.
Using a 13mm open ended spanner(a 45 degree bend near the head will ease access)
unscrew the securing nut from the spindle and remove the potentiometer from the bracket.
Reassembly is the reverse order.
To set the pot, ensure the pinion is central on the rack, disengage the pot by pressing on the
sprung white gear and turn the pot spindle fully clockwise. Then rotate 4.5 turns anticlockwise
(10 turn pot), the potentiometer should read approximately 13.6 Kohms across red and blue
wire (disconnected) or 1.67 Volts (connected).
Re-engage the pot to the middle of the motor drive rack.
Note.- fine adjustment is available on the electric controls.
This wheel is for Transportation and should be adjusted
1mm above the ground. ie. 1mm Higher than the other
four wheels. Loosen the shoulder bolt and with a 19mm
open ended spanner rotate the cam until setting is
achieved, re-tighten the shoulder bolt.
To Replace the Drive Motor.-
To Replace the Potentiometer.-
To Position Stability Wheel.-