Service Manual
Contents
1. CoLibri ros Repair and Replacement Work Removal of the work surface and the protection covers To gain access to the various components that need to be changed it may be necessary to remove the work surface and or the protection covers Before carrying out any repair and or maintenance work the unit must be switched off and the electrical power supply must be disconnected by pulling out the plug Wait until the machine has cooled down IS Failure to observe the warnings set out relieves the supplier from any direct or indirect liability in the event of damage and the warranty shall be immediately forfeited V Removal of the work surface Rest the unit in a vertical position NI R Rue ae no Lo _ _ _ 2D iy Using the hexagonal spanner allen spanner a supplied with the unit unscrew the 2 fixing screws b of the work surface c and remove the latter from its support brackets SESS gt m Data V Removal of the side protection covers Using a suitably sized star screwdriver d unscrew the 2 fixing screws e of the side protection cover f and remove the latter If necessary repeat the procedure on the opposite ay side of the welding head CoLibr VT TT TTTTTTtdooTtTttTTtTttiiZZ777_ _ __ _ POC ket Service Manual 7 V Removal of the lower protection cover Remove the work surface as indicated above and then turn the2. re insert the power cable x r s z CoLibr 16 Service Manual POC ket LD Replacement of the control board When necessary proceed as follows to replace the control board of the unit 1 Working as set out above remove the work surface the lower protection cover I To have greater access and to make the work easier also remove the idle roller and the rubberized roller 2 Usinga suitable hexagonal spanner unscrew the 3 screws a which hold the board b 3 Disconnect all the cables connected to the board by extracting the relevant connectors terminals c and d Extract the board from the machine replace it and reconnect all the cables The colouring and the configuration of the cables connectors facilitate correct re assembly I In any event and in order to avoid incorrect connections we recommend that the positioning of the various cables be noted before disconnecting them Remember to reconnect the earth cable e using the screw pin provided Handle the control board with care and take all the necessary precautions against electrostatic charges 4 Finally fasten the board in the pre arranged position using the hexagonal screws Thereafter re install the parts removed e g idle rubberized rollers reposition and fasten the lower protection
3. replaced and or the entire apparatus at the end of their life are components with a high environmental impact For this reason we do not recommend that they be disposed of with solid urban waste You should rather use the services of a specialized company and or comply with the local rules and regulation in force See the replacement procedures contained in the paragraph entitled Repair and Maintenance Work as regards the identification location of the various items mentioned ar CoLibri 20 Service Manual POC ket cm WISAN SYSTEM CoLibri System spa Viale Ortles 54 a 20139 Milano ITALY Telephone 39 02 5220181 Telefax 39 02 522018 20 Numero Verde 00 318170 Website www colibrisystem com E mail colibri lint it
4. the laws in force If necessary specialized companies must be used for their disposal Only work in accordance with the instructions given Carrying out procedures or work other than those specified may cause irreparable damage and or give rise to potentially dangerous situations If necessary contact the Manufacturer to obtain additional information Te CoLibr 2 Service Manual POC ket CoLibri nes xX Trouble Shooting A list of the most common problems relating to the CoLibr Pocket book covering machine 1s set out below The relative corrective actions to be taken are described for each of the problems IS The symbol indicates that the detailed description of the repair replacement work is set out in the paragraph entitled Repair and Replacement Work Probable cause and remedy The unit does not switch on The power cable is not connected properly the green ON LED does not light up check that the power cable a is correctly plugged in and that the main switch b is turned to I ON position Power cable damaged Check the cable a and if necessary replace it Control board not functioning properly Check the board and if necessary replace it The book covering unit does Start cycle levers not working properly Make sure that both the not work levers to start the cycle are firmly pressed simultaneously When both levers are correctly pressed the red BUSY LED should tu
5. welding head over Using a suitably sized Phillips screwdriver g unscrew the 2 fixing screws h of the lower protection cover i and remove the latter IS The lower protection cover cannot be removed without removing the work surface After disconnecting the power Q from the unit wait a few minutes before removing the lower protection cover IS When handling the welding head with the work surface removed always grip it using the handles 1 and not the surface support brackets shoulders 2 This is done to avoid the contrast idle roller 3 from being dislodged In the event of the roller becoming dislodged from its housing widen the support brackets slightly 3 and replace the pin s of the roller in the housing During this operation pay attention to the position of the spring 4 viewing the welding head from below the spring must be ON the roller pin If this is not the case the machine will not work properly 8 Service Manual CoLibr COVER SYSTEM Pocket CoLibri res COVER SYSTEM Description of the Repair and Replacement Work A detailed description of the repair and replacement work is set out below Replacement of the welding bar Replacement of the microswitch that detects whether the lever has been pressed Removal replacement of the idle roller Removal replacement of the rubberized roller Replacement of the motor Replacement of the driving be
6. cover and the work surface Finally re insert the power cable CoLibr TT POC ket Service Manual 17 Pos CoLibri COVER SYSTEM Replacement of the cycle counter When necessary proceed as follows to replace the cycle counter 1 Working as set out above remove the work surface the lower protection cover 2 Using a suitable screwdriver or a similar tool exert pressure on the blocking tab a of the cycle counter b to unhook it from the anchoring step and make it enter the opening c to insert the counter Repeat this procedure on all the remaining blocking tabs 3 Disconnect the connector d and then extract the counter to be replaced complete with cables and connector from the related insertion opening c located in the welding head structure 4 First insert the connector and the cable of the new counter in the opening c Thereafter insert the counter 1n the opening and exert pressure on it until the blocking tabs a hook onto the anchoring steps Re insert the connector d I Check that the counter is correctly positioned before locking it in place Reposition and fasten the lower protection cover and the work surface Finally re insert the power cable o AXVv 2 r _ CoLibr 18 Service Manual POC ket A nes Replacement of the Start cycle lever When necessary proceed as follows to re
7. d to 1st level service in respect of the abovementioned equipment Look after the instructions manual carefully and keep it in a place that is known and easily accessible If necessary the Customer may request a copy of this document for example where the original document is damaged by making written request to CoLibri System S p A undertaking in each case to return the damaged copy The manufacturer denies any liability for possible inaccuracies contained herein arising out of printing or transcription errors In addition the manufacturer reserves the right at any time to make changes aimed at improving the product AlI the trademarks referred to herein are trademarks which are owned by or which are registered in the name of the individual producers and as such are protected CoLibr Service Manual POC ket CoLibri Table of Contents Introduction and Identification of the Main Componentts Warnings and PreCQautions cccccccccccccccccccccccccccccccececccceeceeeeeeeeeeeeeeeeeeeeess DIO II Repair and Replacement Work ii Removal of the work surface and the protection covers Description of the Repair and Replacement Work Replacement of the Welding Bar lt lt lt lt lt lt 5 Replacement of the microswitch that detects whether the lever has been pressed Removal replacement of the idle roll
8. ent of the microswitch that detects whether the lever has been pressed When necessary proceed as follows to replace the microswitch es that detects whether the lever to start the cycle has been pressed I Remove the side protection cover in the manner described above Using a suitably sized Phillips 6 screwdriver unscrew the 2 screws a that hold the microswitch b to be replaced 2 Remove the microswitch from its housing and using a suitable soldering iron unsolder the wires c from the sockets to disconnect the microswitch Thereafter solder the wires c to the sockets of the new microswitch IS Work very carefully when unsoldering soldering the wires to the microswitch Check the strength of the soldering when the replacement has been completed To avoid damage do not touch parts of the unit and or the microswitch with the soldering iron 3 Insert the new microswitch which has been connected into its housing and fix it in position using the screws Check that the switch is functioning correctly by pressing the start cycle lever and making sure that it clicks this indicates that the microswitch has been activated Reposition and fix the side protection cover that was removed Finally re insert the power cable IS To avoid damaging the microswitch do not overtighten the fixing screws Before repositioning the side protection cover make sure that the connection wires are not pinched or bent excess
9. er Removal replacement of the rubberized roller Replacement of the motor lt lt lt lt lt lt lt lt Replacement of the driving be t lt lt lt lt lt lt lt lt lt lt Replacement of the control board Replacement of the cycle counter Replacement of the Start cycle leVer lt lt lt ONIONIZLIZIIRIRIRIIRIAIIIIEAE Pocket m EEE page 1l ine page 2 s page 3 page 7 mm page 7 mm page 9 dana page 9 REA page 11 ma page 12 sula indi Set page 13 iaia page 14 acc page l6 PEREIRO page 17 vere page 18 er page 19 ma page 20 Service Manual CoLibri nes COVER SYSTEM Introduction and Identification of the Main Components The CoLibri Pocket book covering machine is a semi automatic system used to cover any type of book or publication and may also be used to file save and protect documents photographs plans and objects Covering books or publications of any shape and size becomes a very quick and easy task using the CoLibri system s special transparent covers that are available in various sizes In fact no more than 20 seconds are needed to apply a resistant and perfectly adherent protective cover In addition the transparent cover is not sticky 1t do
10. es not alter the book cover and may be removed and replaced at any time When the book covering machine was designed the main aim was to create a ready to use compact unit that would be suitable for carrying out trimming and welding operations of covers in a safe simple clean and perfectly squared manner All these characteristics have been perfectly integrated in the CoLibri Pocket a hi tech system which is accurate down to the last detail and which is also light handy fast and cost effective The system 1s particularly suitable for stationery shops bookshops schools and libraries In addition because it 1s fast and easy to use the CoLibri Pocket book covering machine is also the ideal solution for professional offices where architects editors photographers etc can use it to file projects documents sketches and drawings or to put objects photographs and printouts into envelopes The unit is comprised of the following main components 1 Welding Head including control board motor roller and tearing counter roller 2 Welding Bar 3 Work Surface 4 LEDs to signal the status of the unit 5 Cycle Counter 6 Cycle Start Levers with micro 6a to detect whether the lever has been pressed 7 Supply Socket 8 Power cable 9 Main switch BES sevicemena COVER SYSTEM IS The supply also includes a set of accessories a screwdriver an allen spanner user documentation etc For more informat
11. ice Manual POC ket nea Removal replacement of the rubberized roller When necessary proceed as follows to remove and replace the rubberized roller motor driven 1 2 3 4 Remove the work surface and the lower protection cover in the manner described above With the welding head turned over working on the right hand side signalling LED side insert the head of a screwdriver a or other similar tool between the rubberized roller b and the support bracket c Use the tool as a lever to extract the roller pin from the housing situated in the support bracket I To prevent breaking the support bracket work very carefully without exerting excessive force Thereafter the roller c can be easily extracted from the other end powered side and replaced if necessary When re installing the rubberized roller we recommend starting the insertion from the motor side making sure that the gear d of the roller is correctly inserted inside the driving belt e When the installation is completed check and if necessary reset the belt so that it is parallel Reposition and fasten the protection covers and the work surface Finally re insert the power cable CoLibri TT POC ket Service Manual 13 mo CoLibri COVER SYSTEM Replacement of the motor When necessary proceed as follows to replace the motor that drives the rubberized roller Operating as set out above remove the wo
12. ion of the cover envelope e g where the trimming is not clean or there is poor welding Make sure that the switch 1 2 is set to position 2 then turn the trimmer B in a clockwise direction to increase the welding time adjustment range 3 5 to 7 8 sec t CAUTION With selection switch set to position 2 and trimmer B completely turned the welding bar may be burnt after a few trimming operations Poc k TT C et Service Manual 5 Problem The trimming operation is not performed correctly follows The cycle counter is not updated on the completion of a cycle Lever s to start the cycle broken or damaged for example if the unit is dropped 6 Service Manual CoLibri COVER SYSTEM Probable cause and remedy Driving belt for the rubberized tear roller is broken or worn Check and if necessary replace the defective part IS We recommend replacing the driving belt after approximately 20 000 30 000 trimming cycles this can be checked with the cycle counter Rubberized tear roller damaged Check and if necessary replace the defective part Idle roller damaged or incorrectly positioned Check and if necessary replace the defective part Control board not functioning properly Check the board and if necessary replace it Cycle counter not functioning properly Check and if necessary replace the defective part Replace the damaged part Pocket
13. ion on the equipment installation connection and proper use of the CoLibri Pocket book covering machine kindly consult the User Manual Warnings and Precautions To avoid irreparable damage to the equipment and or to avoid potentially dangerous situations the warnings set out below must be followed ts The manufacturer will not be held liable for any direct or indirect damage arising out of the failure to observe the warnings contained herein All the procedures and interventions described in this manual must be performed exclusively by qualified and authorized personnel Before disassembling and reassembling the components of the unit and in any event before working on the unit ensure that the power cable is disconnected The socket used to power the unit must be close to the unit and must be easily accessible so that it can be switched off immediately in the event of an emergency In view of the presence of electronic components e g control board take the necessary precautions against electrostatic discharges which might irreparably damage such components Where it is necessary to remove any protection device in order to properly work on the machine the device must be re assembled and its correct positioning must be checked when the work ts finished and before restarting the unit All the materials which have an impact on the environment and which must be removed pursuant to any repairs carried out must be disposed of according to
14. ively Use the channelling provided to house the wires In addition check that the silicon covering d is correctly inserted in its housing CoLibri POC ket Service Manual 11 Pes CoLibri COVER SYSTEM IS Sometimes the microswitch es may fail to work because the related pin 1 is incorrectly set To set the intervention point of the microswitch proceed as follows using a suitable hexagonal spanner allen spanner remove the fixing dowel 2 and then screw or unscrew the pin until the correct setting is reached Thereafter reinsert and tighten the fixing dowel 1 Removal replacement of the idle roller When necessary proceed as follows to remove and replace the idle roller 1 Remove the work surface in the manner set out above 2 Grasp the idle roller a with one hand and pull it towards the interior of the machine With the other hand slightly widen the support bracket b This allows for the roller pin to be removed from the housing set in the support bracket The roller can now easily be extracted from the other end and if necessary replaced Reposition and fasten the work surface Finally re insert the power cable IS When re inserting the pin s of the roller in its housing pay particular attention to the position of the spring c viewing the welding head from below the spring must be ON the roller pin If this is not the case the machine will not work properly TT CoLibri 12 Serv
15. lt Replacement of the control board Replacement of the cycle counter VVVVV VV VV Replacement of the lever that starts the cycle Replacement of the Welding Bar When necessary or after approximately 5000 6000 trimming cycles the welding bar must be replaced as follows 1 Remove the work surface as indicated previously then using a suitably sized Phillips screwdriver a unscrew the 3 fixing screws b of the welding head c 2 To work more easily turn the welding head over Using a screwdriver or a similar tool not sharp remove the wire e which powers the welding bar from the connector d To do so apply a levering action to the wire covering Repeat the procedure on the other side CoLibri TT POC ket Service Manual 9 3 Extract the welding bar f from 4 its housing and replace it with the new welding bar The reference tabs prevent the bar from being incorrectly positioned Insert the wire h which powers the welding bar into the connector plug g Use a screwdriver or a similar tool not sharp to push the wire into the connector plug by exerting pressure on the wire covering Repeat the procedure on the other side CoLibri COVER SYSTEM After having correctly positioned the power wires inside the connectors tighten the 3 fixing screws of the welding bar and re install the work surface Finally re insert the power cable 10 Service Manual A Replacem
16. n the required assistance and information To change the welding time two trimmers A and B and a selection switch 1 2 are available main switch power cable connector side switch off the main switch and 0 Before starting the operation disconnect the power cable Using the screwdriver supplied with the machine adjust the trimmers A or B working as follows I The welding time adjustment must be performed in stages checking whether the results are satisfactory after every step In particular DO NOT turn for each step the trimmers more than of a turn either in a clockwise or in a counter clockwise direction If after the welding trimming operation excessive plastic gloss or filaments remain or the cover envelope appears excessively wavy then Make sure that the switch 1 2 is set to position 2 then turn the trimmer B counter clockwise to reduce the welding time If the problem persists even though the trimmer B has been completely rotated in a counter clockwise direction for instance when the room temperature is very high then e Move the switch 1 2 to position 1 then completely turn the trimmer A in a clockwise direction e If the problem persists tum the trimmer A in a counter clockwise direction to further reduce the welding time adjustment range through trimmer A 1 to 3 5 sec If the book covering machine does not correctly complete the welding trimming operat
17. ng machine can only trim and weld CoLibri covers and envelopes or other material approved by the manufacturer see the user manual If the trimming operation is not performed correctly at the right left side or in the middle of the cover envelope then the problem might be caused by an unparallel support surface Try to move the book covering machine 4 to 5 inches to the right or to the left and retry If the problem persists place the machine on another support surface see the user manual TT CoLibri 4 Service Manual POC ket Colibr ros COVER SYSTEM The trimming operation is not being carried out correctly follows Probable cause and remedy The trimming operation is completed over the entire length of the cover envelope but the material is not welded satisfactorily or appears excessively melted plastic gloss generation In this case the problem is caused by an incorrect welding temperature welding time too short or too long I The CoLibri Pocket book covering machine is supplied already adjusted and calibrated for the most common applications installation sites The above problem could then result from an installation site where the temperature does not fall within the permitted range see the User Manual for further details Should you be unsure as to whether you actually need to adjust the weldin temperature kindly contact the manufacturer s technical _department_to obtai
18. ot over tension the belt or overtighten the locking screws Reposition and fasten the protection covers and the work surface Finally re insert the power cable do My CoLibr TT POC ket Service Manual 15 rog CoLibri COVER SYSTEM Replacement of the driving belt When necessary or after approximately 20000 30000 trimming cycles replace the toothed driving belt that drives the rubberized roller operating as follows 1 Working as set out above remove the work surface the side protection cover on the motor side the lower protection cover the idle roller the rubberized roller a the motor unit complete with the belt b gt gt I It is unnecessary to disconnect the power cables c of the motor 2 Using a suitably sized Phillips screwdriver unscrew the 2 screws d that fasten the plate e Remove the plate so that the driving belt f can be extracted 3 Extract the driving belt replace it and then reposition and fasten the plate e using the screws d I Pay particular attention to the positioning of the driving belt f the support pin g on the rubberized roller side must be inside the belt as shown in the figure 4 Re install the motor unit and the rubberized roller Check that the new belt is parallel and tension it following the procedure set out above Then re install the idle motor all the protections that were removed and the work surface Finally
19. place the cycle start lever s 1 Remove the side protection covers in the manner described above 2 Usinga suitable hexagonal pipe spanner unscrew the nut a and the lock nut b which fasten the tie rod c 3 Remove the washer d and then using a suitable tool push the tie rod c inwards until it comes out of the hole e which 1s located on the rod of the start cycle lever f which 1s to be replaced 4 Slide the start cycle lever from its housing and then insert the new lever aligning the hole e with the tie rod 5 Working on the opposite side exert pressure on the tie rod so as to insert the end into the hole e of the new lever f If necessary slightly rotate the latter to facilitate insertion 6 Insert on the protruding part of the tie rod the washer d and then tighten the nut a and the lock nut b Reposition and fasten the side protection covers Finally re insert the power cable CoLibri TT POC ket Service Manual 19 EA CoLibri List of Spare Parts The following table lists the main components of the CoLibri Pocket book covering machine that can be replaced IS When ordering spare parts kindly specify the serial number of the apparatus as well as the code of the part required IS We recommend using only original spare parts The Manufacturer cannot be held liable for damage arising out of the use of parts that are not original IS The parts which have been
20. reg CoLibri COVER SYSTEM Colibr Pocket Service Manual CoLibri LY COVER SYSTEM TC Pocket SERVICE MANUAL Code MAPKT2 0 Edition October 2004 Revision 2 0 z Viale Ortles 54 a ___COoLIbri sysemspa I 20139 Milano ITALY N Telephone 39 02 5220181 Telefax 39 02 522018 20 Numero Verde 00 318170 Co ri Website www colibrisystem com COVER SYSTEM f SYSTEM E mail colibri lint it CoLibr E e POC ket Service Manual es Colibr CoLibri System S p A All rights reserved This manual is intended for use by technicians who perform Ist level service and repair work in respect of the CoLibr Pocket book covering machine and is thus directed at authorised technical staff who are able to correctly interpret the instructions contained herein This document must not therefore be considered simply as a reference document in the event of a breakdown or fault but rather as a preliminary instruction manual to be used to train the personnel who will perform the abovementioned maintenance and repair work The instructions drawings tables and other data contained in this document are technical information of a confidential nature No part hereof may be reproduced and or disclosed without specific authorization from CoLibri System S p A It is expressly prohibited from disclosing the information contained and to use the manual for purposes other than those strictly tie
21. rk surface the side protection cover on the motor side the lower protection cover the idle roller the rubberized roller 0 0 N 2 Usinga suitable allen spanner unscrew the 2 screws a that lock the motor unit b I Support the motor unit with one hand when it is being loosened The screws a remain inserted in their housing even when completely loosened 3 Extract the motor unit b complete with the belt c and disconnect the power terminals d by extracting them Connect and reposition the new motor unit in the housing provided e The shape of the housing is such that the motor unit cannot be positioned incorrectly IS The replacement motor unit is supplied with the driving belt c Pay attention not to invert the polarity when connecting the motor Re insert the terminals in the original position Partially tighten without locking the 2 screws a which lock the motor unit b so that the motor itself has some freedom of movement TT CoLibri 14 Service Manual POC ket CoLibri COVER SYSTEM 4 Re install the rubberized roller f making sure that the gear g is inserted inside the driving belt 5 After having installed the rubberized roller check that the driving belt is parallel and then ensure that the belt is tensioned properly move the motor unit b along the slots h until the driving belt c is tensioned correctly tighten the screws a I Do n
22. rn on Welding bar not correctly powered Make sure that the welding bar power wire c is correctly inserted into the relevant plug in connector d Use a screwdriver or a similar tool not sharp to firmly press the wire into its connector Repeat the operation on the opposite side D Before starting the operation switch off the main switch and disconnect the power cable POC k ca C et Service Manual 3 ros CoLibri COVER SYSTEM Problem Probable cause and remedy The book covering unit does Welding bar damaged or worn out Check and if necessary not work follows replace the defective part IS After approximately 5000 6000 trimming cycles which can be checked using the cycle counter it is recommended that the welding bar be replaced for correct trimming of the covers envelopes Microswitch es which checks that the lever has been pressed is defective Check and if necessary replace the defective part The drive motor of the tearing rubberized roller is not functioning properly Check the motor and if necessary replace it Control board not functioning properly Check the board and if necessary replace it The trimming operation is A pre heating cycle was not carried out Carry out a pre heating not being carried out cycle as instructed in the user manual and try again correctly Covers envelopes made from an unsuitable material are being used The CoLibri Pocket book coveri
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