Signode Little David LD16AE 2.0 User manual

Little David™ Case Sealer
LD16AE 2.0
Automatic Random Case Sealer
Operator’s Manual

LITTLE DAVID™ CASE SEALER
LD16AE 2.0 Operation
Copyright © Loveshaw
Loveshaw, Inc.
2206 Easton Turnpike, PO. Box 83
South Canaan, PA 18459
Tel: [phone] • 570-937-4921
Fax: [phone]
www.loveshaw.com
Loveshaw Europe
Unit 9 Brunel Gate
West Portway Industrial Estate
Andover, Hampshire SP10 3SL
ENGLAND Tel: [phone]
Fax: [phone]

ii
TABLE OF CONTENTS
Introduction ........................................................................................................ 1
Operating Safety.................................................................................................. 2
General Safety Precautions ......................................................................................2
Safety Devices Functional Testing..............................................................................3
Overview.............................................................................................................. 4
Case Sealer Sections ......................................................................................................4
LD16AE 2.0 Machine Specifications .........................................................................5
Installation .......................................................................................................... 7
Machine Preperation .....................................................................................................8
Box Preparation .............................................................................................................8
Operating Procedures ......................................................................................... 9
Start Up ...........................................................................................................................9
Sequence of Operation: ................................................................................................9
Shut-Down Procedure ................................................................................................10
Control Stop: .......................................................................................................................................10
Emergency Stop: .................................................................................................................................10
Machine Sections ...............................................................................................11
tape cartridge .....................................................................................................16
Cartridge Sections........................................................................................................16
Tape Setup ....................................................................................................................17
Troubleshooting................................................................................................ 20
Taping Difficulty..........................................................................................................20
Boxes jamming in machine: .......................................................................................23
Belt drive problems: ....................................................................................................23
Box does not enter machine: .....................................................................................24
Front suppressor does not compress properly: ......................................................24
Taping head adjustment malfunction: ......................................................................24
Taping head crushes box:...........................................................................................24
Kicker does not close rear flap: .................................................................................24

iii
Maintenance...................................................................................................... 25
DAILY MAINTENANCE .......................................................................................25
WEEKLY MAINTENANCE ..................................................................................26
MONTHLY MAINTENANCE ..........................................................................27
Warranty........................................................................................................................28
(This space is intentionally blank. Continue to next page.)

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INTRODUCTION
The LD16AE 2.0 taping machine has been custom manufactures for your specific packaging
requirement. A great deal of care has been exercised by our design and engineering group in the
construction of your highly efficient machine. The highest quality materials have been used for all parts
and components in the fabrication of your machine.
Understandably, a machine as sophisticated as this may require some adjustments from time to
time. If adjustments are necessary, you will find simple instructions outline in this manual.
If you are in doubt about any adjustment, or if a problem occurs which is not covered in this
manual, please call our service department. It is important to be able to describe the problem in full detail.
Most problems can be corrected through a phone call. Should the problem be more serious, we may be
able to off a temporary solution until our field serviceman can get to your plant.
Chapter
1

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OPERATING SAFETY
General Safety Precautions
Before installing, operating or servicing this equipment, read the following precautions
carefully.
This machine is equipped with moving belts. Do not place hands near the rear of this
machine when belts are moving, as fingers may be pinched where belts enter frame. Always
use a roller type exit conveyor and always remove the boxes after they clear the exit end of
the machine.
Observe caution when near cartridge knife or when threading tape. Knife is very sharp,
automatically operated and is linked to the wipe down rollers.
Do not attempt to open or work on electrical box, junction boxes, or other electrical
components without first disconnecting power to the machine. Shock hazard exists if power
is not disconnected.
Do not by-pass any designed-in safety features such as interlocks, guards or shields.
Fully automatic machines are equipped with a rear flap kicker. Do not place any part of the
body near this area without first disconnecting power and air supply.
Do not place hands or body inside confines of random type machines. The side rails and
head operate automatically.
Do not place hands or body inside confines of uniform type machines unless head is
securely locked and power and air are disconnected.
Always disconnect power and air supply (if applicable) before servicing machine.
Chapter
2

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When operating a semi-automatic machine, hold box flaps down at the trailing edge of the
box. Release hands as soon as the belts take the box.
Do not wear jewelry, loose clothing, such as ties, scarves, etc., and long hair should be pulled
back when operating the machine.
Safety glasses should be worn when working with or around machine.
Safety Devices Functional Testing
It is necessary to test the functionality of the safety devices at regular time intervals. The safety
emergency stop function must be tested daily before each and every shift of operation. The
procedure for testing the emergency stop function is as follows:
1. Connect the machine to the main electrical power source.
2. De-press the emergency stop pushbutton on the main electrical enclosure.
3. Press the start pushbutton on the main enclosure. If the machine does not start proceed to
the next step. If the machine does start unplug it from the main electrical power source and
report it to your supervisor. This machine cannot be used until a qualified technician
corrects the issue.
4. Reset the estop pushbutton to its extended state. Push the start pushbutton the machine
should start. With the machine running de-press the emergency stop pushbutton, the
machine should now stop. This confirms that the emergency stop function is working
correctly.
5. Test guard door interlock switches by starting the machine with all of the guard doors
closed. If the machine starts then open each of the guard doors one at a time. Each time a
guard door is opened the machine must stop. Test each guard switch with the machine
running. If the machine does not stop or reset, the machine cannot be used until a qualified
technician corrects the issue.
6. This confirms that the emergency stop function is working correctly.
The overload motor relay must be tested every three months to confirm its operation. This test
can only be performed by a qualify technician since it requires the enclosure door to be opened.
1. Connect the machine to the main electrical power source.
2. Insure that the emergency stop pushbutton is fully extended.
3. De-press the machine start pushbutton. The machine drive motor should start at this time.
4. Open the main electrical enclosure. Use extreme caution not to contact any live conductors.
5. Locate the overload relay and de-press the red test button on the front of the unit. The
machine should stop. If the machine does not stop the overloads relay is defective and needs
to be changed out. If the machine stops the overload relay passes the functionality test.
6. Close the main enclosure door and lock using the turn latch.
Never operate a machine that does not pass the safety functional testing! Report it to
management and have the machine taken out of service until the deficiency is corrected.

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OVERVIEW
Case Sealer Sections
This manual covers several parts of the machine. The following diagram identifies the some key sections
of the machine.
Chapter
3
Head
Assembly
Frame
Assembly
Kicker Assembly
Head Lifting
Assembly
Height Sensing
Assembly
Infeed Gate
Assembly
Actuator
Assembly
Air Tank

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LD16AE 2.0 Machine Specifications
Machine dimensions:
Height: 70”1778 mm
Length : 77” 1956 mm
Width: 35” 890 mm
Standard Discharge Height: 22.25” 565 mm (Optional To Change)
Weight: 650 lbs. 302 kg.
Electrical Requirements:
Standard Voltage: 115V/220V -1 PH - 60 CYCLES
220V - 3 PH - 60 CYLES
Optional: 240V -1 PH - 50 CYCLES
380V -3 PH - 50 CYCLES
440V -3 PH - 50 CYCLES
440V -3 PH - 60 CYCLES
Operating speed:
Belt Speed: 80 ft./min 24.4 m/min
Number Of Boxes Per Min.: Up to 14 depending on box dimensions

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Air Requirement:
0.15 cf. free air per cycle @ 75 psi. 4.2 liter free air @ 5.3 kg per sq. cm.
Machine box capacity:
Length: 8.25” Min - 24” Max 206 mm –610 mm
Width: 4.5” Min – 20” Max 144 mm –508 mm
Height: 4.5” Min – 20” Max 144 mm –508 mm
Closure Material: Pressure Sensitive Tape
Width: 1.5” min – 2” Max 38 mm –50 mm
Max Roll Diameter: 15” 380 mm

INSTALLATION
Always check for any signs that the machine may have been damaged before fully removing it from the
shipping skid. If machine arrives damaged contact Little David immediately to help in filing a claim with the
shipping company.
Exercise care when handling this machine, a sudden jolt or jar may cause serious damage.
Do not remove the shipping skid until machine has been moved to a point of installation. The skid is
designed for easy and safe handling of your machine.
To unpack the machine, lift off the upper crate, and then unfasten the skid. Lift the machine from the
skid and pull the skid away. Remove all packaging material that is used to secure the head and cartridge.
The bed of the machine should be aligned with the roller height of the conveyor. The machine should
be centered on the infeed conveyor roller. The machine should then be leveled. The stripper plate should be
used to adjust any minor height differences.
After the machine is in place and level, connect the machine to an appropriate grounded electrical
connection, (see machine specification label for voltage). Connect the air supply to an air source. The minimum
line pressure is 70 lbs. (5 kg/cm^2).
Before starting the machine, load the tape cartridges with tape and thread the tape. See threading
diagram.
The machine is now ready for operation. Please note that in order to start the machine, the safety gates
must be closed. When the safety gates are opened, the machine will automatically shut down.

Page | 8
Machine Preperation
Conveyor Alignment
IMPORTANT
Elevations for conveyor rollers and stripper plate. Gate roller in “down” position & belt
should provide a smooth box flow into the machine.
Box Preparation
Note: Major flaps should not be inside minor flaps or bent outward far enough to
miss the flap folders. Minor flaps should be vertical or slightly inwards in the case of double wall
boxes. Minor flap score lines must be broken.

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OPERATING PROCEDURES
Start Up
1) Check to see that electricity and air are connected to the LD16AE.
2) Close safety gates. (Machine will not operate if safety gates are open).
3) Depress “Start” button. Drive motors should run/drive and belts should move.
The machine should now cycle automatically when a box enters it.
Caution: Keep clear of the machine. Do not reach any part of your body into the
machine as you may inadvertently trigger some automatic reaction.
Note: if this machine is equipped with a 3-PH motor, check travel direction of
belts –they should move from the infeed end to the exit end of the
machine. If the direction is reversed, stop the machine. Have a licensed
electrician reverse two wires on the main circuit breaker.
Sequence of Operation:
When a box enters the machine, a sequence of operations is initiated. This
sequence takes the form of discrete steps. Each must be sensed and completed before
the next step can proceed. Below, each step is described in two ways: Paragraph “A”
Describes the action of the operating parts; and paragraph “B” describes the state of
the solenoid valves and limit switches responsible for the action. The heading for each
step identifies the sensor controlling the actions of that step.
Chapter
5

Page | 10
Step 1: Box enters the machine
A. (1) Limit switch LD-1 is depressed.
B. (2) SV-1 is de-energized.
Kicker valve brings up kicker up.
Gate cylinder solenoid valve SV-2 is de-energized brining gate up.
Step 2: Box depresses limit switch LS-2
No action
Step 3: Box releases LS-1 (LS-2 is still depressed)
A. (1) Kicker solenoid valve SV-2 is activated.
Kicker comes down.
Gate is still up.
Step 4: Box releases LS-2
A. (1) Gate cylinder solenoid valve SV-2 is Energized Bringing down the gate.
The safety gate switches, LS-3 to LS-6 de-activate the “E”-Stop circuit by
opening any one of the four safety gates. This will stop the machine and de-activate
the main air dump valve. To re-start the machine, safety gates must first be close and
the “E”-Stop push button must be fully extended, then the “Star” push button on the
control station is pressed.
Shut-Down Procedure
Control Stop:
1) Turn selector switch to test position. Wait until machine finishes processing box.
2) Depress emergency stop push button.
Emergency Stop:
1) Depress emergency stop push button.
2) Remove any unmade or jammed boxes before restarting machine.

Page | 11
MACHINE SECTIONS
Infeed gate
The infeed gate when it’s “up” position, prevents boxes from entering the machine; and in its
“down” position, allows box to enter. The infeed gate drops down when the box releases LS-2.
Side rails
The side rails keep a box centered in the machine as it is being processed. The side rail system
consists of two stainless steel tubes mounted to a set of pivoting arms which are interconnected and
manually adjusted. To adjust the side rails, turn the hand knob counterclockwise and place a sample size
box to be sealed on the bed of the machine. Push the side rails in until they are snug against the box; re-
tighten the hand knob. The side rails will stay in this position until they are changed.
Belt drive system - standard
The two drive belts are directly driven by one drive wheel each that is mounted to the gear
reducer output shaft. The front end of the belt runs over a tension roller. The tension roller bracket holds
two guide rollers that automatically center the belts. The belts then run over the idler roller onto the plastic
anti-friction carrier attached to the sheet metal belt carrier.
The two belt tensioning brackets are spring loaded with two tension springs on each. Care should
be taken to insure that these springs are attached to the tension roller bracket after the belts have been
replaced.
To replace a belt, bring the belt lacing to the top and pull the lacing pin. Replace with new belt.
Only factory supplied belts should be used to avoid motor failure due to excessive friction. Each belt is
replaced separately; however, it is advisable to replace both belts at the same time.
Chapter
6

Page | 12
If one or both belts at the exit end of the machine travel to the left or right, the belt lagging on the
drive rollers must be replaced.
To replace the belt lagging, first remove the belt that is traveling out of line. Turn machine on and
with a utility knife, cut about 1/8” off the belt lagging with the point of the knife while the drive roller is
turning. Be sure to place the knife on the roller so that the roller is moving away from the point of the
knife, lift up a section of the cut lagging and pull off until it is removed from the drive roller completely.
This can be done by jogging the machine on and off while pulling the cut strip of lagging. Attach new belt
lagging. Replace the belt and check alignment. The belt will have moved to the opposite side that was cut.
This procedure may have to be repeated until the belts are centered.
Belt drive system - heavy duty
The two belts are driven by a belt pulley system connected to the gear reducer through a chain
drive system. If the chain becomes loose, loosen four reducer bracket screws and drop reducer down until
chain becomes tight. Tighten screws when adjustments have been made.
The belts at the infeed end of the machine travel over the tension rollers. The tension roller
brackets hold two guide rollers each that automatically center each belt. The belts then travel over the idler
roller located at the infeed end of the machine. To replace a belt, bring the belt lacing to the top. Pull the
lacing pin and replace the belt. Only factory supplied belts are recommended and both belts should be
replaced at the same time.
The two belt tensioning brackets are spring loaded with two tension springs on each. Make sure
that these springs are attached to the tension roller bracket after the belts have been replaced.
If one or both belts at the exit end of the machine travel to the left or right, the belt lagging on the
drive rollers must be replaced.
To replace the belt lagging, first remove the belt that is traveling out of line. Turn machine on and
with a utility knife, cut about 1/8” off the belt lagging with the point of the knife while the drive roller is
turning. Be sure to place the knife on the roller so that the roller is moving away from the point of the
knife, lift up a section of the cut lagging and pull off until it is removed from the drive roller completely.
This can be done by jogging the machine on / off while pulling the cut strip of lagging. Attach new belt
lagging. Replace the belt and check alignment. The belt will have moved to the opposite side that was cut.
This procedure may have to be repeated until the belts are centered.
Pneumatic system
The pneumatic system consists of the filter/regulator, two solenoid valves, one kicker valve, the
gate cylinder and the kicker cylinder. The speed controls for the kicker are located on the kicker valve
manifold. Cushion adjustments are located on the kicker cylinder. The gate speed is controlled by the flow
control located on the main pneumatic assembly. The filter is self-draining. The main regulator setting
should be set at 70-75 psi (4.9 to 5.3 kg/cm²). A lockout valve on the main pneumatic assembly is used to
prevent undesired activation of the pneumatic syste

Page | 13
Limit switches and Solenoid valve locations

Page | 14
Kicker
Kicker adjustments should only be done by properly trained persons only. Before making
any kicker adjustments shut power off to the machine and remove all compressed air from the
pneumatic system. Hold kicker so that the cylinder is in its retracted position.
Gap “a” should be approximately ½”. To adjust gap “a”, loosen lock nut and then turn cylinder
rod either clockwise or counterclockwise as required, until the correct position has been reached. Tighten
lock nut when adjustment has been made.
Gap “b” should be approximately 1/8”. To adjust gap “b”, loosen adjusting screw “c”, then raise
or lower kicker until the correct position has been reached. Tighten adjusting screws when adjustment has
been made.
Turn power and compressed air back on and operate the ld16ae. The kicker should come down
very quickly without causing excess jarring to the machine. If needed, control “b” should be turned
counterclockwise as far as practical, and then the lock nut should be tightened. Since the upward stroke of
the kicker should be as slow as practical, control “a” should be turned clockwise, if needed, and then the
lock nut should be tightened.
If kicker hits solidly or bounces at either end of the stroke, the kicker cylinder may require an
adjustment of its pneumatic cushions.
If solid hitting occurs in the “up” position, loosen lock nut and adjust cushion screw “a” on the
rod end of the cylinder using an Allen wrench. Turn cushion adjusting screw “a” clockwise to increase the
cushion effect. Tighten lock nut.
If solid hitting occurs at the end of the downward stroke, adjust cushion screw “b” found at the
other end of the cylinder in the same manner as cushion screw “a”, described above.
To reduce an excess cushion, this is indicated by the bouncing of the kicker, turn cushion
adjusting screw clockwise.

Page | 15
Front suppressor
The front suppressor is designed to keep the box firmly pressed against the drive rollers during
the flap folding operation. The downward pressure can be adjusted by moving the collar on the spring
holding shaft.
Squeezers
The squeezers are used to square up the top of the box and to insure the proper butting of the
flaps in preparation of the tape.
To adjust the squeezers, start a sealed box through the machine and press the “stop” button when
the box is between the two squeezer wheels. Then push each squeezer wheel snug against the box.
Tighten the m8 t-nuts. The machine is now ready to process this size box. If a different size box must be
sealed, the squeezer wheels must be reset.
Counterweight and head adjustment
The counterweight springs, as shown below, are designed to ease the manual up and down travel
of the head. To adjust the head height, turn the small hand knob counterclockwise; then turn the large
hand wheel until the desired height has been reached. Turn the hand knob clockwise to lock the head in
this position.

Page | 16
TAPE CARTRIDGE
Cartridge Sections
Tape tension roller:
This roller is used to maintain constant tension on the tape throughout the life of the tape
roll. Turning the knurled nut clockwise will increase the tension turning it counterclockwise will
decrease the tension.
Wipe down rollers:
These rubber rollers wipe down the tape as the box passes through the machine. the
pressure exerted by the rollers is adjusted by changing the main spring to a different hole in the
connecting link.
Tape guide plate:
The tape guide plate, along with the finger plate, is used to force the tape to “stand up” for
proper application. The tape guide plate moves which forms a corner as the box depresses the wipe
down roller arm. This insures a smooth tight tape application on the leading corner of the box.
The flat surface of the tape guide plate must be tangent with the rubber roller for proper
operation. To make adjustments, rotate the eccentric stop that it bears against.
Chapter
7