Tunkers Liliput 500 User manual

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Liliput 500
Glue machine

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Introduction
The following guide describes the operating procedures of this machine and
was designed to improve the user experience.
It includes important safety and operational recommendations. Carefully reading
these instructions will prevent accidents, unnecessary repairing and downtime
costs and help increasing the reliability and service life of this product.
This operating guide supplements the applicable Regulations for Accident
Prevention and Environmental Protection.
They must always be at hand (on site) when the machine is being used.
This guide must be read and observed by all operators dealing with the
machine, whether:
Operating: including assembly, troubleshooting, removing waste,
precaution, removing additional material.
Cleaning: maintenance, inspection, repair and/or,
Transporting
Make sure these operating instructions are read and observed carefully.
In addition to the Operating Guide, always observe the applicable Regulations
for Safety and Accident Prevention valid in the country of use and on site.

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TABLE OF CONTENTS
1. Safety Instructions.............................................................................. 4
2. Productivity.......................................................................................... 7
3. Legends and Descriptions................................................................... 8
4. Assembly and Operation..................................................................... 10
5. Operating the machine......................................................................... 11
6. Maintenance......................................................................................... 12
7. Troubleshooting.................................................................................... 13
8. Cardboard Attachment.......................................................................... 14
9. Glue coating on edges and in strips...................................................... 15
10. Animal glue attachment....................................................................... 16
11.Service Parts......................................................................................... 17

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1. Basic Safety Instructions
1.1 -Warning and Safety symbols
Special attention must be paid to important messages with the following words:
NOTES –important instructions for appropriate use of the product
ATTENTION –important safety messages on accident prevention
DANGER –important instructions to prevent serious physical injury or property
damages
1.2- Intended use
This machine was designed according to generally recognized technical
standards and safety rules. During its operation, physical injuries to the user
and third parties or damages to the machine and other assets may occur.
All personnel handling the machine must be and aware of any eventual danger
that may occur. The machine must only be used in technical perfect condition in
accordance with the applicable safety rules. Make sure any malfunction that
may affect safety is immediately solved.
This machine is exclusively designed for glue coating. Any other use is not
deemed appropriate and the manufacturer is not liable for damages or
accidents resulting from such use.
1.3–Safety guidelines on site (user’s liability)
Be sure to keep this operating guide constantly at hand and near the
equipment!
In addition to this guide, please observe all other regulations, standards and
accident prevention rules.
Supervising instructions and reports must be included in this operating guide in
order to comply with specific operating requirement. It is highly recommended
that information on job organization, work procedures and supervisors is added
to this operating guide.
The supervisor of the teams in charge of operating the machine must read and
pay special attention to the safety instructions chapter before starting and
operating this device. This is especially important for the persons in charge of
assembly and maintenance before operation.

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Danger: Loose clothing, rings, jewelry and long and loose hair must be
contained as they might cause serious accidents.
Please make sure all safety instructions are kept at hand in the machine!
If any relevant safety or operation change is noted in the machine, please keep
away from the device and immediately report to your supervisor.
No changes must be made to the equipment during assembly or disassembly
that might interfere with safety without prior authorization of the manufacturer!
This also applies to the assembly and installation of safety devices.
DO NOT make any changes to programming of the operating system.
Duly compliance with the general instructions described and specified in the
guide referring to quality control and inspections must be assured.
1.4–Training
All required training must be provided only by a skilled certified instructor with
clearly defined qualification for operation, assembly, maintenance and repair of
the machine.
Make sure only authorized personnel have permission to operate the machine.
Electrical maintenance must be carried out only by qualified electricians or
personnel duly trained under the supervision and guidance of a licensed
electrician according to applicable electrical regulation.
1.5–Safety instructions for machine operation
Be sure all workplace safety rules and guidelines are followed!
Take all necessary measures to ensure the machine is operated only if safety
procedures are observed.
Before operating the machine, make sure all protection and safety devices,
such as emergency button, fairing assembly are in the proper position and
effectively working.
Note: Check for defective parts and malfunction at least once per shift.
If you notice any malfunctioning, safely move away from the machine! Make
sure all problems are immediately repaired!
Ensure no physical damage can be caused to anyone near the machine before
you start it.

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1.6–Maintenance Safety Rules
Always observe the guidelines contained in this operating guide including
operation, maintenance and inspection of the machine specially for replacing
parts! Such tasks must be performed only by qualified personnel.
Machine operators must be informed in advance about maintenance and repair
works to be performed in the machine!
Any work directly interferes with the machine operation, production, assembly or
setup, including its safety features such as inspection and maintenance.
Consequently, downtime and operation activities described in this guide must
always be observed.
Make sure all safety guidelines are observed before you restart the machine
following maintenance and repair downtime.
Leave all handles, steps, hand rails, stairs, and platforms in a safe, clean and
tidy state.
Electronic parts must be regularly supervised. Loose connections and damaged
cables must be immediately replaced.
A second operator must be on site should any emergency stop is necessary.

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2. Productivity
The machine works by coating water-based adhesives on entire bottom
surfaces in the working widths up to 500 mm with theoretically unlimited
lengths.
Coatings of water-based cold and hot glue or latex are possible.
The amount of glued sheets directly depends on its size (length), on the speed
setup in the machine and on the speed operators are handling the equipment.
Maximum speed is 20m/min.
Heat element power: 530 W
NOTE –To better identify service parts, please check the exploded views and
its respective lists at the end of this guide.

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3. Legends and Descriptions
Input-table (10) holds down the sheet at the machine input slot. After aligning
the front edge of the sheet just push it towards input coating roller (11 and 11a).
These coating rollers will drive the sheet to the cylinder. Coating roller (11a) is
driven and coating roller (11) loosely rotates around it.
Coating roller (12) loads and coats the sheet. The glue film is set through the
distance between coating roller (12) and coating scraper (12a). The coating
scraper grabs (transferring) the adhesive from the tray to the coating roller (12).
To increase or thin out coating thickness, rotate knob (13) which will, in turn, lift
or lower the coating scraper (12). Knob (13a) fastens adjustments by the height
variation between coating rollers (12 and 12a). The adjusting shaft (14) is found
between coating rollers (12) and input coating rollers (11 and 11a), which will
drive the sheet through the coating roller (12) making sure the sheet is entirely
glued.
The stripper fingers (15) are loose, facing the coating roller (12). Their purpose
is to separate the sheet from the coating roller (12).
15
12
14
10
11a
11
12a
18
18a
13a
13

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NOTE –On both sides of the
coating roller (12) and the
coating scraper (12a) you will
find shields (16 and 16a) with
seals.
Shields to prevent an
accumulation of adhesive on
rolls that might damage
coating rollers.
_______________________________________________________________
Machine starts-up via the V17-belt
connected to the motor.
16
16a
17

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4. Assembly and Operation
Assembly procedures are completed by the manufacturer and the machine is
delivered ready for use. Optional attachments are sold separately and can be
delivered afterwards. After unpacking you will notice some parts were lubricated
with oil or grease that can be removed using any kind of solvent or gasoline.
Parts stored for longer and inactive periods can also be lubricated for
protection. Coating rollers can be rotated for a few times to make sure all
components are working properly and are noise free.
When motor is purchased as an optional component, make sure the network
supports the motor data recorded during its setup or assembly. Local conditions
must be considered in determining which types of motor will be necessary.
Motor starting-up must be handled only by a qualified professional. When motor
is purchased separately, the client will be liable for acquiring the motor and
pulley and for attaching those parts to the machine.
Connect the power cable to the electrical network supply and the water tray
cable to the power cable found on the back of the digital thermostat to power
the attachment of the animal glue. Check that the equipment is suitable for the
electrical supply.

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5. Operating the machine
The machine is extremely easy to operate.
Ensure the tray is filled with the chosen adhesive so that the coating scraper
(12a) is submerged in glue.
The machine must be supplied with special types of V2A stainless steel coating
rollers in order to work with latex.
Attention - When you are using animal glue, please follow the steps below to
assure a proper adhesive preparation:
1) First pull the trays out and make sure you fill the tray (18a) with 600 ml of
water;
2) After assembling on tray 18a, make sure you add 1.5 kg of glue + 1 liter
of water;
3) Only after thermostat reads 70-75C (158-167F) verify the proper dilution
of the glue (visual checking with a spoon, for example);
4) Fit the trays to the equipment and make sure the glue film is adjusted to
minimum thickness to avoid glue accumulation in the roll. Make sure
motor rotation is established in low up to medium speed.
Adding enough water to the adhesive preparation ensures viscosity is reduced
with the purpose of avoiding resolidification of the adhesive in the first rotations
(first starting minutes) and not interfering with coating rollers proper rotation.
Note: Tray (18a) must be filled with water 2-3 times a day. Make sure the
water does not evaporate completely because this might damage the heating
element. You can check the water level through the hole found on tray (18) and
refill as needed.
The trays must be assembled to the equipment only when thermostat reads 70-
75C (158-167F) and when a low viscosity and proper dilution of the glue (visual
checking with a spoon, for example) is ensured. Make sure motor rotation is
established in low up to medium speed and check if the glue film on the coating
roller (12) is uniform.
As shown on Chapter 3 (Description and Legends), the glue film thickness must
be adjusted using knobs (13 and 13a). Following those adjustments, you can
start gluing the sheets. Be sure to position the sheet on the input-table (10) and
manually moving it towards coating rollers (11 and 11a) which will drive the
material to the coating roller (12) until the sheet is lifted by stripper fingers (15).
Once the material is lifted it is ready to be manually removed. For longer sheets,
grab the leading edge as it exits and guide it back towards the front of the
machine.

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6. Maintenance
Maintenance activities can be easily undertaken.
Make sure you perform regular cleaning and lubrication of the bearings.
During working process, the glue tray must remain fully filled at all times.
Adhesives must have low viscosity and be properly diluted to ensure a good film
control which will determine a better coating. Perform regular cleaning of the
stripper finger blades not to damage sheet edges.
The stripper fingers are shaped to be used in all four sides, just loosen the
screws and rotate them. It’s important to adjust all stripper fingers at the same
height to avoid damages or unwanted marks to the sheets. For short downtime
and breaks, such as lunchtime, it’s recommended to keep coating rollers
running to avoid sticking and to prevent the accumulation of a glue shell on the
adhesive surface.
Longer downtime and breaks require complete cleaning procedures.
6.1 –Cleaning procedures
After working process is complete, a full cleaning procedure is required as
described below.
While motor is in operation at low speed, dislodge the trays from the lateral
structure moving them forward until the coating scraper (12a) is no more
submerged in adhesive. The exceeding glue in the coating rollers drops down
into the glue tray. The bottom tray is removed from the machine. Once outside
the machine, the top glue tray is removed (using animal glue). Next, replace
only the water tray back in the machine. At this point, fill in the water tray till
coating roller (12a) is submerged again, but in water this time. Here you will
notice the coating rollers are starting the auto cleaning processes and all you
need to do is drying them with a damp cloth.
DANGER –Always make sure you stop the motor before performing the action
above.
The stripper fingers can be disassembled for cleaning purposes.
NOTE –Proper and acceptable cleaning of the coating rollers and stripper
fingers assure a longer working life of the equipment.

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7. Troubleshooting
7.1 –Coating failure
Be sure to properly fit the adjusting ruler (14) up to the end of the lateral slot of
the machine. Then, check if the coating failure remains. If not, check if the glue
film is thick enough using knob (13). If the end edge of the sheet does not show
a proper coating, then grab the leading edge as it exits and guide it back
towards the front of the machine.
7.2 –If paper tears
Make sure stripper fingers are properly positioned. Remove all stripper fingers
from the shaft and adjust their height. If they are slightly worn, loosen and rotate
them a bit or replace the blades.
7.3 –Motor is not rotating or is running slowly
Ensure the power cable is properly connected and the electrical supply is
getting to the wall socket.
If no light is on, check fuses. When blown, replace it 5A
In other cases, call a qualified electrical technician.
7.4 –Sheet loaded into the machine.
Make sure the stripper fingers are assembled or properly positioned to prevent
this to happen.
Stop the motor, and slowly turn the roller counter-clockwise, through the shaft
11a, as shown. To pick-up the sheet, lead it out manually.

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8. Cardboard Attachment
The cardboard attachment is a supplementary device needed for gluing hard
materials such as cardboard, leather, and others. This attachment is not
included in the standard machine and must be purchased separately.
8.1 –Cardboard attachment assembly
Operators can easily assemble this attachment to the machine. First, remove
coating roller (11) and adjusting shaft (14) from the machine. Next, correctly
position input-table (20) and the coating rollers support by fastening bolts (21
and 21a).
Ensure belt (24) is assembled over pulleys (22 and 23). If the cardboard
attachment is purchased separately, pulley (22) must be assembled on top of
the shaft by the user. Pulley and attachment as well as belt must be delivered
all at the same time.
8.2 –Knob (25) controls pressure in both pressure rollers of the attachment.
Make sure pressure is enough to stack the sheet (neither high nor low), or else,
the coating application might fail. Be careful not to bear the pressure rollers
against the coating roller (12).
Follow the same steps for gluing procedures, with print side up on table (20).
Coating will be applied on bottom side after manually loading the material
between pressure rollers and coating roller (12).
8.3 –Attachment disassembly for regular operation
Unscrew bolts (21) and (21a) and belt (24) to remove the entire attachment.
22
20
21
21a
23
24
25
25a

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9. Glue coating on edges and in strips
The attachment for glue application on edges and in strips was designed to
ensure the sheet is glued in chosen spots. Strips can be positioned along the
entire shaft width. If the optional strip attachment is purchased separately, make
sure you follow the steps below for assembly.
a) Remove coating roller (12). Assemble shaft (30), gluing rings (31a) and
supporting rings (31b) in desired width and position. Rings (31b) are
merely conductors to prevent the sheet from falling.
b) Adjusting shaft (14) supports carriers (32) for the proper assembly of
shaft (33) on top of which connecting rods (34) are mounted. Connecting
rods and its rollers must be assembled only on supporting rings (31b) to
increase sheet pressure against gluing rings and ensuring a proper
gluing. The entire shaft (14) and its components must be removed when
the strips attachment is used at the same time as the cardboard
attachment.
c) Knobs (35) adjust the scraping rule (36), which was designed to limit glue
build-up in the gluing rings. Get close enough to release a thin glue film,
but make sure not to bear the rule against the coating roller.
d) To return the machine to standard settings and gluing the entire sheet
surface, disassemble all parts described in this chapter and reassemble
the coating roller (12).
30
32
32
34
31a
31b
33
35
36

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10. Animal Glue Attachment
a) Make sure you fill the tray with water before starting the thermostat.
b) Place the glue tray on top of the water tray (already filled with 600 ml
(Liliput 500) and 1 liter (Z8) of water). Next, add around 1 Liter (Liliput
500) and 1.5 Liters (Z8) of water to the glue tray to lower viscosity and
insert the thermometer in the water tray to control temperature.
c) It is recommended to always keep the water tray fully fulfilled to make
sure temperature is controlled, otherwise, water will boil and might
damage the attachment.
Water Dosing Pump
The dosing pump assures controlled water supply to the animal glue tray.
Due to machine’s layout, the glue in the animal glue tray is constantly moving
and getting in contact with heat and dry air. As a consequence, it loses humidity
and viscosity. A dosing pump is needed to continuously supply water to the tray
and sustain glue viscosity. Make sure the water is supplied with the hose
positioned in the center of the tray as shown in the picture below.
As advised before, the glue must be well diluted in the first starting minutes
using the animal glue. Following the first minutes, coating rolls are already
heated-up by the melted glue, so next step is to add another dose of unmelted
glue to rapidly increase viscosity while the pump is still OFF.

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Note: Because of this preparation, ensure the pump is not started before
the viscosity level increases by adding unmelted glue. (This process
might take 10-15 minutes).
The pump must keep running at 20% capacity with the potentiometer reading 2
or 4 (10 or 20) in the control panel after the steps below are reached:
a) Visual viscosity checkup.
b) Some samples must be coated in order to approve viscosity
c) Start working normally, coating nonstop.
d) Unmelted glue must start constantly being added while the
machine is running
Since there are different types of adhesives depending on the supplier, and the
work settings as well as climate conditions are constantly changing, the amount
of water (higher or lower) will have to be customized according to each user.
Besides, different materials demand different viscosity levels.
Based on those variants, managing the water pump use will be different
for each user and each case.
11. Service Parts