Morgana DocuFold Mk2 User manual

ISSUE2 January2008
90-111
MorganaSystemsLimited UnitedKingdom
Telephone:[phone]Fascimile:[phone]
Website:www.morgana.co.uk
AUTOMATICPAPERFOLDINGMACHINE
OPERATORSMANUAL
DocuFoldMk2
SERIALNo.W52097LAANONWARDS

Page2 PAPER
AUTOMATICPAPERFOLDINGMACHINE
DocuFoldMk2
K
IZ
AA
ACBE
FA
FIXEDSIDELAY
BB
D
G
FFEE
S
W
V
U
T
Y
CC
DD
R
Q
X
P
GG

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DocuFoldMk2 SafetyDo’s&Don’ts
SafetyDo’s&Don’ts
Do-operatewiththedesignatedACcurrentonly.Useanexclusiveoutlet,as
overloadingmaycausefireoranelectricshock.
Do-installthepowercordoutofthewaytoavoidatrippinghazard.
Do-bewareoffingertrapswhenreplacingrollercassetteandfoldplates.
Donot-installthemachineinanunstableplacesuchthatittiltsorshakes.
Donot-unplugtheplugorunplugthepowercordfromtheoutletwithawethand,
thiscancauseanelectricshock.
Donot-unscrewandremoveanycoversfromthemachine,asitcancausean
electricshockorinjury.
Do-readthisoperatormanualfullybeforeoperatingthemachine.
Donot-placereceptaclescontainingliquidsonanysurface.
Donot-adjustanypartofthemachinewhilstrollersarerunning
Donot-operatethemachinewithlooseortrailingclothingorloosehair.
Donot-underanycircumstancesremovethefoldplateswhenthemachineis
Donot-underanycircumstancesadjustthepapergatewhenthemachineis
switchedon.
switchedon.

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OPERATORSINTRODUCTIONTOTHEMORGANADOCUFOLDMk2
TheMorganaDocufoldisabrandnewconceptpaper-foldingmachine.Designedtobeusedin
today'senvironmentofdocumentproduction,theMorganaDocufoldcanbeusedbynon-skilled
personnelbyfollowingthiseasytouseoperatorsguide.Thereareveryfewoperator
adjustmentsrequiredonthemachineandour KWIKSTART sectionwillgetyoustartedvery
quickly,butwedorecommendthatyoutakealittletimetoreadthismanual,toensurethatyou
fullyunderstandthemachine.WehavealsoincludedaTIPS&TROUBLESHOOTING
section.Besuretoreadthissection before callingaserviceengineertoavoidanyunnecessary
expense.
OntheDocufoldthefoldplatesandDeliveryRollerwillmoveautomaticallyaccordingtothe
typeoffoldselected.Pleasebeawarethatdifferentweights,humidity,temperatureorthegrain
directionofthepapermaymakethepaperfoldinadifferentpositionaccordingtothematerial.
Somemanualadjustmentmaysometimesbenecessarytoobtaintheexactfoldplatepositionfor
eachtypeofpaper.
KWIKSTARTGUIDE:
1. Setthepapergategap(knobB)totwothicknessofthepapertobefolded.
2. Placethepapertobefoldedontotheloadingtableagainstthefixedsidelay.
3. Unclampthemovingsidelay(knobsA)andslideupagainstthesideofthepaperbutallow
approximatelya1/2mmor1/64inchgapbetweenthemovingsidelayandthepaper.
4. Clampthebackstop(F)ontothemovingsidelayatthebackofthepaperstack.
(Note)Donotattempttoloadtoomanysheetsontotheloadingtableduringsetupasthis
mayaffectthefeedingoperation.
5. Makesureyouhavepowertothemachineandthatknob(S)isturnedontotheONposition.
6. Pushswitch(W)downwardtosetupposition.
7. Slidethesheet-measuringdevice(BB)uptotheblockofpapertobefolded.
8. Lookatthediagramonthemovingside(G)layshowingthevariousfoldtypes.Selectthe
typeoffoldthatyourequiretomakebyturningknob(V),forexampleselectSLforLetter
fold.
9. Liftswitch(W)tothemiddleposition(Run)
10. Pressthesystemswitch(T)andallowthemachineafewsecondstoreachitsoptimumspeed.
11. Pressthefeedswitch(U)downtopulseandthemachinewillfeedthreesheetsforchecking.

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12. ‘Check’will appearon the controlpaneldisplay. If the checksheetsarefoldedcorrectly,
movethefeedswitch(U)totheoff position.
13. Zerothe counterby pressing theset-up switch(W)upwards.If you requireto batch, the
Docufold providesthefacilityto batchin denominationsof10’sfrom10 to 1000.
Tosetbatch, you canselect therequired batch numberby turning thefeedswitch(U)to
off & thenrotating theselectknob (V)until therequired batch quantityappearsinthe
controlpaneldisplay.
14. Pushthefeedswitch downto pulsetostart themachinefeeding thepaper.

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MORGANADOCUFOLDMk2OPERATORINSTRUCTIONS
SIDELAY
Placeasinglesheetofthejobontotheloadingtable.
Releasethesidelayclampscrews(A)andslidethesidelayjustuptothesheetsothatthereis
abouthalfamillimetreclearanceor1/64inch
Tightentheclampscrews.
PAPERGATE
Adjusttheheightofthepapergateusingknob(B)(clockwisetolower,anti-clockwisetoraise)
sothattheclearanceabovethevacuumrolleristwothicknessesofthepapertobefolded.Do
notmakethisadjustment,whenthefaceofthepapergateisaboveaholeinthevacuumroller,
ifitis,rotatethevacuumrollerbyhandtobringthemetalbetweenholesbelowthepapergate.
Onthismachine,thepapergateisfixedinanoptimumpositionandcannotbemoved
backwardsandforwards(horizontally).
SUCTIONOPENING
Thesuctionslotinsidethesuctiondrum,maybeadjustedbyreleasingknob(C)andswinging
theknobinthedesiredposition.Lighterstocksincludingbondwillrunbestwiththeknobset
totheleft.Forheavierstocksandcurled-upstock,movetheknob(C)totherightuntila
satisfactorypositionisobtained.
AIRDISTRIBUTIONKNOB(D)
Dependingonthelengthofthesheet,theairdistributionknob(D)shouldberotatedtosupply
theairtothecorrectportsasfollows -
Position1-ThisisforshortsheetsA5or8"longwithonlyport1open
Position2-ThisisforsheetsA4or11"longwiththefrontportandport2open
Position3-ThisisforthelongestsheetsA3or17"withthefront portandport
3open.
Position0- Inthisposition,onlyport2isopenandcanbeusedonlongsheets
withthecurlupwhereyouneedtoblowairintothecentreofthestack.
Thesesettingpositionsareonlyaguideandsomeexperimentationmayobtainabetterresult
withnon-standardsettings.
(Note)Position1feedsmostpaperstocksandsizes;thustheairdistributionknobcanbe
leftinthispositionformostjobs.

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AIRSEPARATIONKNOB(E)
Thisknobcontrolstheamountofairthatisfedtothepaper.Themachinewouldnormallyrun
withthisknobsetatthe'High'position.Ifthemachineisrunwithlessthanapproximately20
sheetsontheloadingtable,orrunningthejobtothelastsheet,thisknobshouldbesettothelow
position.
BACKSTOP(F)
Thisisplaceduptotheendofthepaperstackandclampedtothemovingsidelay(G).
SHEETMEASURING(BB)
Whenpushingset-upswitch(W)downtoset-up,thepositionofthesheet-measuringdevicewill
bedisplayedonthecontrolpaneldisplay.Itwillmeasurethelengthofastackofpapertoan
accuracyof0.1mm.Bypushingthesheet-measuringdeviceuptothebackofthestackofpaper,
itwillallowtheDocufoldtocalculatethefoldlengthaccordingtothetypeoffoldselected.
Note: -Ifthedigitafterthedecimalplaceflashes,itismeasuringbetween0.1ofamillimetreand
isnotamalfunction. Alwayspushthesheet-measuringdeviceagainstthepaperstackwhen
adjustingfoldtypes.
FOLDPLATES
ALWAYSUNPLUGPOWERCONNECTIONSBEFOREREMOVINGFOLDPLATES.
Fitting
Fitthefoldplatesintotheirrespectivepositions(longfoldplateupperandshortplatelower),by
locatingthefrontpins(I)intothelongslotsandcarefullyslidingforwards(withouttwisting)
untiltherearpinscanbelocatedintotheshortslots.Whenfullyinposition,pulldownthefold
platetolockintoposition.Connectthepush-inpowerconnectors –shortleadtoplate1(upper)
&longleadtoplate2(lower).
Settings
Thefoldplatelengthsaresetautomatically.
FoldplateTilt
Seerollertilt.
SETTINGTHEVACUUMBLEED(GG).
Situatedonthefrontofthefeedtable,theVacuumBleedKnobisusedtoallowmorecontrol
ofthesuctiononthevacuumdrum.
Whenlightweightpaperof90gsmandlowerisbeingfedthroughthemachineturntheknob
clockwisetoreducethepossibilityofmarking,ordamagetotheleadingedgeofthepaper.

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Manual&FineAdjustment
Thefoldplatelengthcanbeadjustedmanually.Youmayneedtomakethisadjustmentto
achievetheexactcorrectlengthoffold.Button(CC)willselecttheupperfoldplate&button
(DD)thelowerfoldplate.Tomakeamanualadjustmenttothepositionoftheupperfoldplate,
pressandholdtheupperfoldplatebutton(CC).Thedimensionoftheupperfoldplatewillnow
bedisplayedinthecontrolpanel.
Note: -Theupperfoldplateshowsthedimensionofthefrontedgeofthe papertothefirstfold,
thelowerfoldplateshowsthedimensionfromthefirstfoldtothesecondfold.
Byturningtheselectknob(V)whilststillpressingandholdingtheupperfoldplatebutton(CC)
thefoldlengthoftheupperplatecanbelengthenedorshortened.Turningtheselectknob(V)
clockwisewilllengthenthefoldplatelengthandbyturninganti-clockwiseitwillshortenthe
foldplatelength.
Thedigitsbeforethedecimalpointshowninthedisplayareinmillimetres,each‘click’ofthe
selectknob(V)representsincrementsof0.1ofamillimetre.
Toadjustthepositionofthelowerfoldplate,press&holdthelowerfoldplatebutton(DD)and
adjustthelengthasdescribedabove.
Whenyouhaveadjustedthefoldlengthdimension,moveswitch(W)uptotheRunposition.
Theplateswillthenpositionthemselvesaccordingtothefoldlengthsyouhaveselected.
Withswitch(W)intheRunpositionthelefthandsideofthecontrolpanelwilldisplaytheletter
‘U’whichindicatesausersettingfollowedbyaletterthatindicatedthefoldtype.Forexample
theletters‘UL’wouldindicateaUsersettingbasedonaLetterfoldandtheletters‘UH’would
indicateaUsersettingbasedonaHalffold.
Tocheckthefoldpositionaftermakingamanualorfineadjustment,pressthesystemswitch
(T)andthenpressthefeedswitch(U)down.Themachinewillfeed3checksheetsandstop.
Aftercheckingthe3-rdsheet,ifthefoldpositioniscorrect,movethefeedswitchuptotheoff
positionandthen immediatelydowntothepulsepositionandthemachinewillstarttooperate.
Ifaftercheckingandfurtherplatepositioningisrequired,repeattheaboveprocedure.
Thefinalfoldplateanddeliverystackersettingscanbe‘stored’forretrievalatalaterdate,see
‘ToStoreAProgramme’.

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RollerTilt
Lever(AA)shouldalwaysbesetinthe‘0’(square)position.Toadjustfoldingoutofsquare
youcanmovetherollerassemblyinthe+or –directionbyreleasingknobs(Y)andmoving
lever(AA) –alwaysre-tightenKnobs(Y).
+-

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StackingRoller
Thestackingrollerwilladjustautomaticallyaccordingtothefoldtypeselected.
Manualorfineadjustmentforthepositionofthestackerrollercanbemadebypressingand
holdingthestackerrollerbutton(EE)onthetopofthecontrolpanel.‘Roll’andadigitfrom1to
9willappearinthedisplaypanel.
Thehigherthenumber –thefurtherdownthebeltstackerbedtherollerwillbe.
Toadjustthestackingrollerpositionupordown,pressthestackingrollerbutton(EE)andturn
theselectknob(V)tooneofthepre-setpositions1to9.
Youshouldadjusttherollerpositionsothatwhentheworkisstoppedbythestackingroller,it
liesflatonthedeliverywithoutlyingontheslopingplate(R)andwithoutthegreenbelts
showingbetweentheslopingplate(R)andthefoldedsheet.
ToStoreAProgram
Aftermakingamanualadjustmentorfineadjustmenttoeithertheupperfoldplate,lowerfold
plateorthestackingrollerposition,youcanstorethesettingforretrievalatalaterdate.Thiscan
beusefulwhenjobsneedtoberepeated.
Pressswitch(W)downtotheset-upposition,usingtheselectknobturnuntilyoureacha‘P’with
asingledigitnumbernexttoit.Youhavefrom‘P1’to‘P6’toselectandcanstoreuptosix
programmes.Whenyouhaveselecteda‘P’number,pressandholdthefeedswitch(U)down
until‘StorEd’appearsinthedisplaypanel.
Toselecta‘P’programmeatalaterdate,pressset -upswitch(W)downselecttherelevant‘P’
numberbyrotatingtheselectknob(V)andpushtheset-upswitch(W)toRun.
Presssystemswitch(T)&movethefeedswitch(U)toPulse.
EmergencyStopSwitch(S)
Thisswitchalsoservesasthemainisolator. Itisimportantthatthemachineisswitchedoffat
theendofthe daysrunning,pressthisswitchtoisolatethemachine. Toswitchbackon,
rotatetheswitchheadclockwise.
MainSwitch(T)
Themainswitch(T)willrunthewholemachine.Thisswitchincorporatesacircuitthatswitches
offevery100secondswhilst thefeedswitchUisintheoffposition.Themainswitchmay
disengageseeminglyatrandombutthisisanormalfunctionandmaybeinstantlyre-engaged.

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FeedSwitch(U)
Switchesthefeedonandoff.
Neverleaveinthepulseorstreampositionwhenmainswitch(T)isoff. Thisswitchisused
toselectthetypeoffeed,eitherpulseorstream.Inthecentralpulsepositionthefeederpauses
betweeneachsheetandallowsagapof160mmbetweeneachsheetastheyenterthefold
rollers.Thisgappreventssheetsoverlappinginsidethefoldplates,whichlessensthechanceof
staticbeinggeneratedandwilldecreasepaperjams.
Zigzag/concertina,engineeringandgatefoldscanonlyberunonpulse.Byholdingswitch(U)
down,thefeedmodewillswitchtostreamfeedwhichwillfeedpaperwithlittleornogap
betweenthesheets.Streamfeedwillincreaseproductivitybutfoldingaccuracymaybeslightly
impaired.Youcanonlyusestreamonletter,halfordoubleparallelfolds.
Thepulsefeedwillcopewithalltypesoffoldincludingperforating.
BatchKnob(V)
Thebatchknobisarotaryswitchandturningtheknobslightlysothatitmovesoneposition
willcausethedisplaytoshowthesetbatchquantity.Movingtheknobfurtherwillchangethe
batchquantityinmultiplesof10upto990.Stoppingthefeedinthemiddleofabatchwillnot
affectthebatch.Whenthemachinebatches,thefeedwillstopandthedisplaywillshowthe
batchquantitywithaseriesofdashes.Feedingwillresumeafterashortperiod.Ifbatchingis
notrequired,turnthebatchknob(V)untilitreads0inthedisplaypanel.When0isshownafter
turningbatchknob(V) thecounterwillonlytotalcount.
Overlap
Themachinehasabuiltinsystemthatwilldetectanysheetthatoverlapsanothersheetbyat
least20mm.Whenthishappens,feedingwillstopandthemainswitchwillswitchoff,
preventingseriousjamsandthedisplaywillshow'O-LAP'.Notethatthisisnotadouble
detectorandwillnotdetectalldoublesheetfeeds.Howevertheoverlapsystemisanindication
ofatendencytodoublesheetfeedandthereforethepapergateshouldbeloweredslightlyand
thepaperstackshouldbefannedoutmorethoroughly.
SpeedControl(X)
Themachinehastworunningspeeds,whichareselectedbythehandle(X).Pushingthehandle
sharplyintothemachinewillselectthefastspeed.Pullingthehandlesharplyoutwards will
selecttheslowspeed.Theslowspeedisrecommendedwhenrunningworkthatisdifficultto
stack,forexamplewhenperforatingorfoldinganengineeringtypefold.

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PLUG-INPERFORATOR
Thepluginperforatorunitisusedforperforatingscoringandwhenfoldingcardcover
stockandshouldbestoredontherearstowagehooks.
ALWAYSUNPLUGPOWERCONNECTORSBEFOREREMOVINGFOLDPLATES
ORPLUG-INPERFORATOR.
Removethe secondfoldplateandfitthecatchtrayinpositionbyhookingitoverthe
openingforthesecondfoldplate.Thepluginperforatorunitthenlocatesthesameasthe
foldplateandagain,takecarenottotwistwhenfittingintoposition.Youmayneed to
turnthehandwheelandpushtheperforatorunitinwardstoengagethedrivegear.Plugin
thelowerfoldplatepowerconnectorintotheperforatorunit.‘PerFin’willappearinthe
displaypanel.
Forallapplications,theunitissetonthebenchusingthescaletoindicatepositionsof
thebladesandhubs.Itisimportanttospreadthehubsevenlyacrossthewidthofthe
worktoreducetheriskofpaperjams.
Whenperforatingorscoringwithoutfolding,theupperfoldplatemustberemoved
andreplacedwiththelowerfoldplate.
Ensurethatthetiltrollerisatzero,plugintheupperplateconnectorintothelowerplate.
Topreventdamagetotheunusedupperplatewhenscoringorperforating,storesafelyon
thestowagehooksatthereversesideofthemachine.
Pressset-upswitch(W)downandthenuptotheRunposition,thebuiltindeflectoron
lowerfoldplatewillcloseautomaticallytothedeflectposition.
Note: -theDocufoldwillautomaticallyrecognisethatthelowerplateisintheupper
platepositionandthattheplug-inperforatorunitisinthelowerplateposition.Youdo
notneedtomeasurethepaperlength.
Startthemachinewiththemainswitch(T),andselectslowspeedbypullingoutlever
(X)sharply.Pressthefeedswitch(U)topulse.
Themachinewillfeedsheetsforcheckingandwilldisplay‘Perf3’ifthecounterhas
beensettozero.Torunthejobswitchfeed(U)tooffandthenpulse.
Note: -Alwaysrunperforatingorscoringjobsonpulsefeed.
FITTINGPERFORATERBLADES
Theperforatorbladesaresplitintotwomatchinghalvesandarefittedtotheupperhubs
asshowninthedrawingusingthefourscrewssupplied.

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UPPERTYREANDHUBASSEMBLIES
LOWERHUBS(SOLID)LOWERPERFSHAFT
FRAMEPADUPPERPERFSHAFT
DRIVEHUB
1,0mm
(3/64")
EDGEOFSHEET
1,0mm
(3/64")
1,0mm
(3/64")
RECOMMENDEDSCORERSET-UP
SCALE
1,0mm
(3/64")
1,0mm
(3/64")
SCORER
1522 21 20 19 18 17 16 4 3 2 1 0567891011121314
DRIVEHUB
SCALE
RECOMMENDEDPERFORATORSET-UP
EDGEOFSHEET
FRAMEPAD
UPPERPERFSHAFT
LOWERHUBS(SOLID)LOWERPERFSHAFTANVIL
PERFORATINGBLADE PERFORATORSTRIPPER UPPERTYREANDHUBASSEMBLIES
22 21 20 19 18 17 16 4 3 2 1 0 567891011121314

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SETTINGPERFORATORS
Upperandlowerhubscanbepositionedontheshaftbyunscrewingthe2mm-grubscrew.
Slidethehubwiththebladeattachedalong,theshaftintopositiontocorrespondtothe
workusingthescaleasaguide.Forexample,toperforate20mmfromtheedgeofanA4
sheet,youwouldsetthebladeat190mm(210minus20).Whenpositionedre-tightenthe
2mm-grubscrew. Important -DoNotOverTightenThisGrubScrew
Slidethehubwiththeanvil,uptotheperforatorbladeandtheremainingupperandlower
hubs,setasthedrawing,rememberingtospreadthemtosupportthesheetfullyacrossits
width.
Cliptheperforatorstripperadjacenttotheupperhubasshown.Plugtheunitinto
position,fitthesheetsmootherintopositiontoholdthesheetsdownandrunthemachine
attheslowspeedtocheckposition.
Adjustthebackstopandsideguidetosuitthework.
Forworklongerthanthebackstopwillallow,removethebackstopandusetheextended
backstopthatislocatedunderneaththe catchtray.
Thereisafullrangeofperforatorbladesavailableasfollows:
Forfineperforation 56tooth -PartNumber1.99-41
ForPaper 28tooth -PartNumber1.99-12
ForheavierStock 20tooth -PartNumber1.99-10
Forusewith blades Anvil -PartNumber1.99-35
Slittersetforcutting -PartNumber1.99-13
SCORING
Itispossibletoscoreworkusingthepluginperforator.Thescorersaresplitintwo
halves,fittedtotheuppershaftandsetasshown inthedrawingusingthescaleonthe
unitasaguidetoposition.Thelowerhubsaremoveduptobutjustclearofthescoring
blade.Theactualgapiscriticalandmayrequiresomeexperimentationtoobtaina
satisfactoryscoreline.Aswithperforating,theremaininghubsmustbespreadtosupport
thesheetfullyacrossitswidth.
Scorersavailable:
TypeA PartNumber 6.99-05formostcard
TypeB PartNumber 6.99-06fordeepscore
TypeD PartNumber 6.99-09forpaper

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FOLDINGCARD
Forbestresults,thecardmaterialshouldalwaysbeprintedcrossgrainasthiscausesless
resistancewhenfolding.Prescoringofcardstockisalsorecommended
Byusingthepluginperforatorunittodelivercard,theproblemofthestockcurlingwill
beminimised.Puttheupperplateintotheupperplatepositionandtheplug-inperforator
unitintothelowerplateposition.Pluginpowerconnectors -upperintoupperfoldplate
andlowerintoperforatorunit.
Setthebackstop,sheetmeasuringdeviceandsideguidetosuitthework.Pressthe
switch(W)downtoSet-upandthenuptoRun.Plate1willautomaticallymovetohalf
thelengthofthestackofcoverstockprovidedthesheetmeasuringdevice(AA)isin
position.Fineadjustmentsmaybenecessarytoupperplateasdescribedin‘FoldPlate
Manual/FineAdjustment’.
Itisrecommendedthatwhenfoldingcard,themachinebesettobatchaftertwenty
sheets,whichwillalloweasyoffloading.Forlongerrunsanoptionalreardeliverybelt
stacker(Assy.No.9-09-01)isrecommendedtobeused.
Intheeventofapaperjam,thesensorwillcutoutthemainswitch.Themainfoldrollers
arelinkedtoaclutch,whichwillpreventsheetscontinuingtofeed.
PAPERJAMS
Ifforsomereasonapieceofpaperjamsinthemachine,removeandcheckinsidethefold
plates.Ifthereispaperjammedaroundthefoldrollerstakeholdofarollerandwind
thembyhandtoremovethejam.Ifitisimpossibletowindtherollerbyhand,remove
therollerassemblyasdescribedbelow.Afterclearingapaperjam,alwayscheckinside
thefoldplate(seeFoldPlateSection)tomakesurenotornpiecesofpaperarejammed
insidetheplate.
ROLLERASSEMBLY -REMOVAL
Thecompleterollerassemblyunitcanberemovedfromthemachinesimplyby
unscrewingtheknobs(Y)oneachsideandtakingholdoftherearrollerandliftingout
theunit.Thisisbeneficialtoclearpaperjams,tocleantherollerandformaintenance.
Withtherollerassemblyremoved, thesafetycircuitpreventsthemachinefromrunning.
Replacetherollerunitinthereversesequence.Cleantherollerswithastiffbrush
betweenthegroovesusingQDwashsuppliedbyMorgana.

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ROLLERADJUSTMENT
TheuniquefoldrollerdesignofyourMorganaDocufoldwillfoldmostpaperstockswithoutthe
needforadjustment.Ifyouhavearequirementtofoldverydelicateorthickerstockorre-
feedingtoproduceacross-foldthefoldrollergapcanbeeasilyadjustedasfollows: -
1. Removetherollerassemblyfromthemachineasdescribedabove.
2. LoosentheCapHeadScrewontheoperatorssideoftherollerthatyouwishtoadjust(any
ofthe3outerrollers)usingthe5mmBondus‘L’wrenchprovided&releasetheM8lock
nutonthenon-operatorssidewiththe13A/Fspannerprovided.
3. Insertthe4mmhexballdriverintothesocketscrewattheendoftherollershaftandrotate
intherequireddirectiontoadjusttherollergap.
4. Thegraphicson theinsideoftherollersideplateshowwhichwaytoturntherollertoadjust
thegaprelativetothecentreroller.
5. Re-tightenthehalfnuts&capheadscrewstolocktherollerintoposition.
6. Repeatprocedureforeachrollerthatyouwishtoadjustand thenreplacetherollerassembly
intothemachine.
7. Resettherollertiltknob(AA)backtothezerocentralpositionandscrewintheClamping
knobs(Y).
RotateRollerinthisdirectiontoincreaseGap
(eachgraduationequals0.1mmofgapadjustment)
SectionThroughRollerAssembly
RotateRollerinthisdirectiontoincreaseGap
(eachgraduationequals0.1mmofgapadjustment)
RotateRollerinthisdirectiontoincreaseGap
(eachgraduationequals0.1mmofgapadjustment)
CentreRoller
3OuterRollers(Adjustable)

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SENSORCLEANING
Thesensorstodetectandcountthesheetsarelocatedontheendoftheballholderjust
nexttothefoldrollerunit.Ifthecounterisfailing,thesensorscanbeaccessedfor
cleaningbyremovingtherollerassemblyasdescribedabove .Cleanbyusingasoft
brushordampcloth.
FOLDPLATES -MAINTENANCE
Thefoldplatescanbeopenedupformaintenance,cleaning,etcbyremovingthelock
knob(H)andremovingthetwobolts(Z).Thefoldplatewillthenopenuptoenable
paperjamstoberemovedorcleaning.

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FOLDINGTIPSANDTROUBLESHOOTING:
SHEETSDIFFICULTTOFEED
Checkthatyouhavenotgottoomanysheetsinthefeeder.Heavy-coatedstockwillnotfeedas
highapileasforexample80-gsmcopierpaper.
Makesurethemovingsidelayisnotpushedintootightlyagainstthepaper.Similarly,ifthe
movingsidelayissettoofarawayfromthepaperstack,thiswillallowtheairtoescapeinstead
ofblowingthroughthepaper.
Makesurethatthegapunderthepapergate(B)isnotsettoolow.
TurntheAirseparationknob(E)tothehighposition.
Makesurethatairdistributionknob(D)issetcorrectly.
Ifthepaperwidthvariesyoumayneedtotrimthesheetstothesamesize.
Ifthepaperiscurlingupwardsthesuctiondrummaynotbeabletopullthesheetdownwardto
wraparoundthedrumforefficientfeeding.Youmayneedtobendthesheetsdownwardprior
toloading.
DOUBLESHEETFEEDING
Makesurethegapunderthepapergate(B)isnotsettoohigh.
Makesuretheairdistributionknob(D)andtheairseparationknob(E)areatthecorrectsetting.
Inextremecasesyoumayneedtoseparatethesheetspriortoloading.
MakesureyourunonPulsenotStream.
FOLDISNOTSQUAREORCONSISTANT
Checkthesheetsareallexactlythesamesize andaresquarebeforefoldingasyoucanonlyfold
accuratelyifthematerialisconsistent.
Makesureyouhavenoforeignbodiessuchasfragmentsoftornpaperinsidethefoldplatesor
thefoldrollers.
Checkthatthefoldplatesarelockedandlocatedsecurelyandthattherollertiltmechanismis
settozeroandlocked.

Page20 PAPER
PAPERWILLNOTSTACKCONSISTENTLY:
Makesurethefeedisconsistentbeforeattemptingadjustmentstothestacker.
Setthestackingrollerpositionasdescribedinthemanual.Sometimesasmallrepositioningof
therollerwillimprovethestacking.SeeStackingRoller.
Ifthepaperistoocurlywhenbeingdelivered,placethecatchtrayandpluginperforatingunit
withbladesdisengagedintopositionanddeliverouttheback.Thisappliestosinglefold
applicationsonly.Iftwofoldsarerequired,youmayneedtoreducetheweightofstockto
achievethedesiredresults.
PAPERWILLNOTDEFLECTWHENUSINGONEFOLDORPERFORATING:
Checktomakesurethatthesecondplateisbeingusedasthedeflector.
Makesurethattheplateislocatedsecurelyand thatthedeflectorbariswoundrighttotheend.
Setthetiltrollermechanismtozero.
Checkthatthematerialisnottooheavytodeflect.
TOTALANDBATCHCOUNTERNOTWORKING:
Cleanthesensorsasdescribedinthemanual.
O-LAPKEEPSAPPEARINGON COUNTERBOARD
Iftheoverlapkeepstrippinginandcuttingoffthemachine,firstcheckyouarenotfeeding
doublesandresetthefeeder.
Overlaptrippingcanalsomeanthatthemachineisslowingslightlywhichmaymeanthe
materialistooheavy.
Check thatyouhavenoforeignbodiesortornpaperstuckinsidetheplatesormachine.
‘NOPLATE’INDISPLAY
Checkfoldplateorpluginperforatorpowerconnectors.
MACHINEWILLNOTRESET
YourDocufoldisaminicomputer;youmusthaveacleanconsistent powersupply.Switchoff
atpowerswitch(S),wait20secondsandre-power.