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Ladybird I Folder 

March 2014 

Intro 

Service Manual 

III

 

  

 

HOW TO USE THIS DOCUMENTATION 

 

Introduction 

 
This section provides the Service Representative with information pertaining to the 
organization and use of this service documentation, and includes the following supportive 
reference data: 
Reference Symbology 
Signal Nomenclature 
DC Voltage Range Specifications 
 

Section 1: Service Call Procedures

 

This section is used by the Service Representative as a structured process for determining the 
type and sequence of actions that are performed during a service call.  The Service Call 
Procedures section is designed to assist in the effective recognition of machine symptoms 
and problems, as well as

,

 providing instructions for the maintenance and corrective actions 

that are required to return the machine to the full operating condition. 
Section 1 of this service documentation is the entry level for all service calls.  The Service 
Representative should begin each service call with the Initial Actions/Systems Checks 
procedure found in Section 1. 

Section 2: Repair Analysis Procedure 

Section 2 of this documentation contains the Repair Analysis Procedures (RAPS) necessary 
to repair all faults other than the folds faults.  The Service Representative will be referred to 
this section from some other section of this documentation during the service call.  When a 
machine defect or fault has been resolved by using a RAP, the Service Representative should 
immediately return to the point in the service call from which section 2 was entered. 

Section 3: Fold Quality 

This section contains the Fold Quality Repair Analysis Procedure used to diagnose fold 
quality defect problems within the Ladybird Folder. 

Section 4: Repair and Adjustment  

This section contains all repair and adjustment procedures for the machine.  Repairs (REPS) 
and adjustments (ADJS) are identified by the use of a standard chain prefix number. 

Section 5: Parts List 

This section contains a list of spare parts for the machine. All parts list page reference 
numbers begin with the letters 'PL', followed by a prefix number, a decimal point, and a 
sequential number used within the subsystem. 

Section 6: General Procedures 

This section contains procedures and Information of a general nature that apply to the 
machine. The General Procedures subsection contains frequently used procedures that relate 
to the diagnosis, the set-up, or the operation of the machine. 
It also includes specific information that is pertinent to the operation of the machine, but will 
not be found in any other part of the service documentation.  This information may include 

product codes, environmental operating data, installation space requirements, paper and 
electrical specifications. This subsection may also contain information regarding 
supplemental tools and supplies, general service notes, a glossary of commonly used terms, 
and a Change Tag Index of authorized machine modifications and retrofits. 

Section 7: Wiring Data 

This section contains support information to assist in the electrical diagnosis of machine 
problems and is a central location for electrical wiring diagrams.  This section is used in 
conjunction with other diagnostic or maintenance procedures that are contained in other 
sections of the service documentation.. 
 
 

OTHER INFORMATION 

 

The Use of Caution, Warning, and Note statements 

 

Information relative to the completion of a task in a safe or thorough manner will be supplied 
in the form of a Caution, a Warning, or a Note statement.  These statements are found 
throughout the service documentation. 
Cautions, Warnings, and Note statements appear before the steps to which they apply.  These 
statements should be read before continuing to the next step in a procedure. 
The definition of a Caution, Warning, or Note is as follows: 
 

Caution

 - A Caution statement indicates an operating or maintenance procedure, practice, or 

condition that, if not strictly observed, could result in damage to, or destruction of, 
equipment. 
 

Warning

 - A Warning statement indicates an operating or maintenance procedure, practice, 

or condition that, if not strictly observed, could result in personal injury or loss of life. 
 

Note

 - A Note statement indicates an operating or maintenance problem, practice, or 

condition that is necessary to accomplish a task efficiently. 
 

The Use of Acronyms, Abbreviation, Specific or Unique Terms, and Conventions

 

A list of acronyms and abbreviations used in this service documentation will be found In the 
Reference Symbology subsection, contained elsewhere in this section. 
 

 

 

Summary of Contents for LadyBird I

Page 1: ...LadyBird I Folder Service Manual D860101X March 2014...

Page 2: ...RES III SECTION 2 REPAIR ANALYSIS PROCEDURE III SECTION 3 FOLD QUALITY III SECTION 4 REPAIR AND ADJUSTMENT III SECTION 5 PARTS LIST III SECTION 6 GENERAL PROCEDURES III SECTION 7 WIRING DATA III OTHER...

Page 3: ...iar with the use of any special tools that are required to service this product Service Documentation Revisions This service documentation may be subject to periodic revision in order to reflect any c...

Page 4: ...eneral Procedures This section contains procedures and Information of a general nature that apply to the machine The General Procedures subsection contains frequently used procedures that relate to th...

Page 5: ...are commonly found In GERA equipment These symbols are included as an aid to understanding the representations used in the Circuit Diagrams CDs AC and DC Voltage References The expected AC and DC volt...

Page 6: ...that is closed Switch relay contacts with momentary contacts shown normally open Switch relay contacts with momentary contacts shown normally closed Connectors numbering This symbol indicates the num...

Page 7: ...entire drawing was the configuration before being changed by the tag number within the circle Signal Nomenclature The signal is named to imply the condition of the machine when the signal is available...

Page 8: ...rch 2014 Service Manual 1 1 SERVICE CALL PROCEDURE 1 Service Call Procedure 1 SERVICE CALL PROCEDURE 1 1 SERVICE CALL PROCEDURES 1 2 INITIAL ACTION 1 2 FOLDER REGISTRATION 1 3 SYSTEM CHECKOUT 1 3 CSE...

Page 9: ...lassify the folder problem by using RAP and Fold Quality Section Perform RAP REP ADJ Final Actions FOLD QUALITY PROBLEMS Section 3 Fold Quality FOLD QUALITY SELECTION INDICATION Go to the Generic RAP...

Page 10: ...e delivered to the output tray Y N Refer to the Initial Action in order to classify the problem and begin your repairs Evaluate the print folding The folding quality is acceptable Y N Go to Section 3...

Page 11: ...2 2 Sensor default status chart 2 2 STATUS MESSAGE RAPS 2 1 TWO GREEN LED LIT ON TOGETHER 2 1 FAN FOLDER UPPER POCKET SENSOR COVERED RAP ALL 2 1 FAN FOLDER LOWER POCKET SENSOR COVERED RAP ALL 2 2 ala...

Page 12: ...o locate it count number of beeps ERROR Message RED LED FLASHIG Beeps every 30 sec ENTRY ALARM 1 Beep FAN ALARM 2 Beeps CROSS ALARM 3 Beeps SENSOR DEFAULT STATUS CHART Since the folder has many sensor...

Page 13: ...Control Panel red Led flashing and emitting 4 beeps The default sensor Led status is light on To locate Upper Pocket Sensor C3 refer to Electric Diagram Procedure The folder sensor C3 led should on i...

Page 14: ...ROBLEM_REPORT_FORM_ladybird pdf ALARM STATUS RAPS FOLDER ENTRANCE ALARM RAP ALL Use this RAP when the folder stops and the red led is flashing and 1 beep This occurs when the print jams at folder entr...

Page 15: ...on the Electric Diagram for missed input voltage 12Vdc or sensor signal sent to main Controller PWB Is sensor operating correctly Y N Replace sensors Please check Sensor C2 C3 and relative RAP if pape...

Page 16: ...er does not work open after the Power Supply replacement call to Gera Service Team by filling Problem Report Form available at http www gera it wp content uploads report_form PROBLEM_REPORT_FORM_ladyb...

Page 17: ...ce Manual 3 1 FOLDING QUALITY 3 Folding Quality INITIALIZATION PROCEDURE 3 2 FOLD DEFECTS 3 2 FOLD QUALITY DEFINITION 3 2 FOLD QUALITY RAPS 3 3 FQ 1 FOLD SKEW 3 3 FQ 2 FOLD DAMAGE 3 3 FQ 3 FOLD DIMENS...

Page 18: ...at cause media damage before attempting to fix fold quality problems Some media damage problems can cause fold quality problems To fix folding quality problems 1 Compare the fold defect to the Fold Qu...

Page 19: ...ly the Cross Folding infeed referring the quick guide Stair and or Skew effect A Wrong Folder and Printer Alignment A Perform Front Rule Adj 1 3 FQ 2 FOLD DAMAGE Defect Probable Cause Corrective actio...

Page 20: ...fold setup A Cross Trim Adjust panel 2B Print exits unfolded from the fan folder A sensor does not detect the print correctly B NO FOLD program selected A Perform Fold selector position B Check curren...

Page 21: ...OLDER ADJUSTMENTS 4 5 ADJ 1 1 Mobile Roller Right Side 4 5 ADJ 1 2 Mobile Roller Left Side 4 5 ADJ 1 3 FRONT RULE 4 6 ADJ 1 4 INFEED GROUP PARALLELISM 4 6 3 PROGRAM ADJUSTMENT PROCEDURE 4 7 ADJ 1 1 PR...

Page 22: ...Overturn down the Assembly carefully until to horizontal position Figure 4 1 Upper Infeed Group Overturn REP 1 2 LEFT COVER REMOVAL 1 Switch off the folder 2 Perform Rep 1 1 In feed Group Overturn 3...

Page 23: ...t Cover Figure 4 3 Right Cover Reamoval REP 1 4 POWER SUPPLY FRONT COVER REMOVAL Before open the Power Supply Front Cover that s advisable to lift up the mobile blue collector to avoid it obstacles th...

Page 24: ...Manual 4 4 REPAIR AND ADJUSTMENTS REP 1 5 POWER SUPPLY REAR COVER REMOVAL 1 Switch off the folder and disconnect the Plug 2 Remove the Plate showed below by unscrewing the two fixing screws Figure 4 5...

Page 25: ...left side Adjustment Figure 4 7 Mobile roller left side Adjust the Mobile Roller distance between the folding rollers Screw clockwise increase the distance Unscrew anticlockwise decrease the distance...

Page 26: ...ent 1 3 check the parallelism between the infeed group both side and the printer exit Adjustment Perform the parallelism adjustment Acting firstly on left attaching bracket to obtain equal distance fr...

Page 27: ...both for program P1 210 mm fan and program P2 190 mm fan LONG PLOT Panel mm Address 1A 210 Ad2 2A 210 Ad1 ADJ 1 2 PROGRAM P3 305 and P4 297 CROSS Program P3 305 mm Cross Fold Size Panel Mm Address A1...

Page 28: ...Ladybird Folder March 2014 SPARE PARTS LIST Service Manual 5 Spare Parts List PL 0 1 SENSORS 5 2 PL 0 2 ELECTRONIC PARTS 5 3 PL 0 3 MOTORS 5 4 PL 0 4 KIT 5 5...

Page 29: ...d Frontal Sensor 3 7 8 C695419X Barrier Sensor 4 C850405X Datalogic Lateral Sensor ITEM DESCRIPTION 1 Start toothed rollers Sensor 2 No Corss Sensor 3 Start Feeding Sensor 4 Advancing Sensor 5 Start M...

Page 30: ...nual 5 3 SPARE PARTS LIST PL 0 2 ELECTRONIC PARTS ITEM CODE DESCRIPTION 1 C940403R POWER SUPPLY 230v 2 C340418X RELAY 24VDC 3 C960423R PWB MAIN CONTROLLER REV 3 4 C960403R DRIVE CONTROLLER 5 C940405R...

Page 31: ...Ladybird Folder March 2014 Service Manual 5 4 SPARE PARTS LIST PL 0 3 MOTORS ITEM CODE DESCRIPTION 1 FEDING MOTOR 2 C860405X FLAP MOTOR 3 CONVEY MOTOR 4 MAIN MOTOR 5 E1 SOLENOIDE 4 M3 5 1 M1 2 MT 3 M2...

Page 32: ...Ladybird Folder March 2014 Service Manual 5 5 SPARE PARTS LIST PL 0 4 KIT CODE DESCRIPTION CARE PACK...

Page 33: ...860 SERVICE MANUAL 5 SPARE PARTS...

Page 34: ...specifications 6 2 CONTROL PANEL 6 3 Folding Programs 6 3 ELECTRONIC PWB 6 4 Main Controller PWB 6 4 Drive Controller PWB 6 4 JC 11 CONNECTOR 6 5 DIAGNOSTIC 6 6 Input Output Test 6 6 MAINTENANCE 6 7 F...

Page 35: ...ge Requirements 115V 2A 60Hz 230V 1A 50Hz Audible Noise Average Continuous 58dbA max run NEGLIGIBLE Stand by Environmental Relative Humidity 35 to 85 Temperature 60 to 90 Fahrenheit 15 to 32 Celsius P...

Page 36: ...market the folder is intended for Selection Key PRESS TO SELECT THE FOLD OUTPUT PACKAGE FOR PRINT INTRODUCED MANUALLY Press to perform Manual Eject and clear the folder jams Reset Key Performs RESET F...

Page 37: ...from Power Supply AMP 2x1 Drive Controller PWB The PWB Drive Controller is located inside the lower panel of the folder It contains the CPU and firmware that controls the stepper motor Main Fan Folde...

Page 38: ...er into the Folder through the Connector JC11 is for the information necessary between Folder and Printer stop the Printer with Folder Alarm Cut Signal and Starting Folding Process ITEM on JC11 DESCRI...

Page 39: ...nload the GERA UTILITY 2 5 from GERA web site and install it Download Utility Rel 2 5 Download the zipped file who contains defaults values ini file parameters and firmware Firmware Parameter and Ini...

Page 40: ...Poor print transportation lack of pressure Rubber rollers Poor print transportation Sensors Poor print sensing resulting in lower fold quality Every 15000 meters folded Maintenance activities Check C...

Page 41: ...Switch off on the folder If one green LED is lit on the upgrading was successfully done If two LED is lit on do the upgrading procedure again Folder Adjustment Connect the USB serial cable to the P5...

Page 42: ...made increase the folder safety O Optional If the modification is not necessary and can be installed by CSE choice The serial number of the folders that mount the modification MFG SERIAL N The TAG nam...

Page 43: ...Ladybird Folder 03 Mar 2014 Service Manual 6 10 GENERAL PROCEDURE...

Page 44: ...Ladybird Folder March 2014 Service Manual 7 1 WIRING DATA 7 Wiring Data 1 FOLDER WIRING DATA 7 2 BSD 1 1 ELECTRICAL MAIN DIAGRAM 7 2...

Page 45: ...Ladybird Folder March 2014 Service Manual 7 2 WIRING DATA 1 FOLDER WIRING DATA BSD 1 1 ELECTRICAL MAIN DIAGRAM...

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