Munsch GMAK-420 User manual

MUNSCH Kunststoff-Schweißtechnik GmbH Issue 05.2017/Rev. 01 Page 1/20
Operating Instructions
Type: GMAK-420 / GMAK-620 Serial No.: ______________
GMEK-420 / GMAK-620 Article No.: ______________
These operating instructions contain important information to
be observed for hand extruder operation and maintenance.
It is therefore imperative that they be read and their contents fully
understood by the operators before the hand extruder is placed in
service.

Hand Extruder GMAK-420, 620 / GMEK-420, 620
Page 2/20 Issue 05.2017/Rev. 01 MUNSCH Kunststoff-Schweißtechnik GmbH
Scope of delivery:
Please check that the delivery is complete.
The delivery comprises:
1 Hand extruder 1 extruder support
3 Nozzles
3 Compression nozzles (420)
2 Compression nozzles (620)
1 Granulate funnel with transparent lid
1 Hot air hood
1 Welding shoe
3 Preheat nozzles (other sizes on request)
Contents
1 GENERAL......................................................................................................................................................................4
2 SAFETY..........................................................................................................................................................................4
2.1 I DENTIFICATION OF INFORMATION IN THE OPERATING INSTRUCTIONS .......................................................................5
2.2 P ERSONNEL QUALIFICATION AND TRAINING ..............................................................................................................5
2.3 R ISKS RESULTING FROM NON - OBSERVANCE OF THE SAFETY INSTRUCTIONS ..............................................................5
2.4 S AFE WORKING PRACTICES ........................................................................................................................................5
2.5 S AFETY INSTRUCTIONS FOR O PERATOR / OPERATING PERSONNEL .............................................................................5
2.6 S AFETY INSTRUCTIONS FOR MAINTENANCE , INSPECTION AND MOUNTING .................................................................7
2.7 U NAUTHORIZED MODIFICATIONS AND SPARE PARTS ..................................................................................................7
3 TRANSPORT AND STORAGE...................................................................................................................................8
3.1 T RANSPORT ...............................................................................................................................................................8
3.2 S TORAGE ...................................................................................................................................................................8
3.3 R ETURN TO M UNSCH .................................................................................................................................................8
4 PRODUCT DESCRIPTION .........................................................................................................................................8
4.1 A PPLICATION RANGE .................................................................................................................................................8
4.2 G ENERAL ...................................................................................................................................................................8
5 STARTUP AND SHUTOFF..........................................................................................................................................9
5.1 G ENERAL ...................................................................................................................................................................9
5.2 P REPARATION ............................................................................................................................................................9
5.3 S TARTING THE HAND EXTRUDER .............................................................................................................................10
5.4 W ELDING WITH THE HAND EXTRUDER .....................................................................................................................11
5.4.1 Introducing the welding rod............................................................................................................................11
5.4.2 Replacement and aging of welding material...................................................................................................11
5.4.3 Welding direction / rate..................................................................................................................................11
5.4.4 Interruption of work........................................................................................................................................11
5.4.5 Shutoff.............................................................................................................................................................12
5.4.6 Transport/Storage...........................................................................................................................................12
5.5 S ET TEMPERATURES AND MATERIAL - DEPENDENT RECOMMENDATION , FOR THE INSTALLATION OF THE NOZZLE AND
COMPRESSION NOZZLE .........................................................................................................................................................12
Set temperatures .............................................................................................................................................................12
6 MAINTENANCE/INSPECTION ...............................................................................................................................14
6.1 M AINTENANCE / INSPECTION OF GMEK/GMAK HAND EXTRUDER ..........................................................................14
6.2 D ISMANTLING ..........................................................................................................................................................14
6.2.1 Overview of spare parts/attachments..............................................................................................................14
7 MALFUNCTIONS, CAUSES AND REMEDIES......................................................................................................16
7.1 T ROUBLE - SHOOTING ................................................................................................................................................16
7.2 F AULT DIAGNOSIS ....................................................................................................................................................16
8 TECHNICAL DATA ...................................................................................................................................................18

GMAK-420, 620 / GMEK-420, 620 Issue 05.2017/Rev. 01 Page 3/20
EG-Konformitätserklärung des Herstellers
nach der EG-Maschinenrichtlinie 2006/42/EG Anhang II, Nr. 1 A
EC-Declaration of Conformity by the Manufacturer
as defined by machinery directive 2006/42/EC, Annex II, No. 1 A
MUNSCH Kunststoff-Schweißtechnik GmbH
Im Staudchen
D-56235 Ransbach-Baumbach
Germany
Mr. Johann Dausenau,
Kunststoffschweißtechnik GmbH,
is authorised to compile the technical documentation.
We hereby declare that the hand extruders
Machine type: Hand extruder Hand extruder
Type designation: GMAK-420
GMEK-420 GMAK-620 GMEK-620
are in accordance with all relevant provisions of the EC Machinery Directive.
The following harmonised standards (or parts of these standards) were applied:
DIN EN ISO 12100: 2010 DIN EN 13732-1: 2008
In addition, the hand extruders are in accordance with the following EC-directives, standards, codes and regula-
tions:
EU Low-Voltage Directive 73/23/EWG EU EMC Directive 89/336/EC
EN 60204-1 (VDE 0113 Part 1): 2011 DIN EN 55014-1: 2012
EN 61029-1 (VDE 0740 Part 500): 2010 DIN EN 55014-2: 2009
VDE 0701 Part 1: 2008
RoHs 2011/65/EU
This industrial tool complies with the aforesaid standards insofar as it is used at the contractually agreed condi-
tions. The operator is responsible for this.
In the event of any modifications to the machine/unit or use not as intended, this declaration becomes invalid
unless the manufacturer’s prior written approval has expressly been given.
Ransbach-Baumbach, 12.05.2017 Dipl.-Ing. Stefan Munsch
Managing Director

Hand Extruder GMAK-420, 620 / GMEK-420, 620
Page 4/20 Issue 05.2017/Rev. 01 MUNSCH Kunststoff-Schweißtechnik GmbH
1
General
These operating instructions must always
be available at the place of use of the hand ex-
truder.
The objective of these operating instructions is to
support operators in familiarizing themselves with the
hand extruder and in using its functions for the in-
tended service.
These operating instructions provide important in-
formation for the safe, workmanlike and economical
operation of the hand extruder. Their observance
helps avoid danger, minimize repair costs and down-
times, enhance reliability, and extend the service life
of the hand extruder.
These operating instructions must be observed by all
persons working with/on the hand extruder. Such
work includes, for instance:
•operation,
•maintenance, inspection and repair
•transport.
The hand extruder may only be mounted, operated
and maintained by trained personnel.
In addition to the operating instructions and the
national and local accident prevention regulations
applicable at the place of use, the acknowledged
technical rules for safe and proper working practices
must be observed.
These operating instructions provide basic infor-
mation to be observed for operation and mainte-
nance. For this reason, it is imperative that they be
read by the specialist personnel/Operator prior to
placing the hand extruder in service and that they
always be available at the place of use.
Apart from the general safety instructions under sec-
tion “Safety“, also the special safety instructions giv-
en under the respective sub-sections must be ad-
hered to.
Non-observance of the safety instructions
may cause hazards to persons and the environment
or damage to the hand extruder.
Moreover, failure to observe the safety instructions
may lead to the forfeiture of any damages.
Non-observance of the safety instructions may in
particular involve the following risks:
•failure of important hand extruder functions,
•hazards to persons due to electrical and mechan-
ical impacts including risk of burns,
•hazards to the environment due to vapour-phase
hazardous substances,
•risk of fire.
2 Safety
These operating instructions provide basic infor-
mation to be observed for operation and mainte-
nance. For this reason, it is imperative that they be
read by the specialist personnel/Operator prior to
placing the hand extruder in service and that they
always be available at the place of use.
Safe operation of the hand extruder presupposes
that the instructions under section 1 – General – of
these operating instructions are complied with. In no
case must the limit values indicated be violated.
Intact and unaltered hand extruders conform to the
applicable codes and standards and meet all regula-
tory limit values regarding EMC (electromagnetic
discharges and interference immunity). For the coun-
try-specific limit values to be observed, the Operator
should consult the local electric utility. Nevertheless,
the hand extruders emit electromagnetic fields within
the acceptable limits. Electromagnetic fields may
interfere with the operation of vital electronic devices
(e.g. cardiac pacemakers). Persons wearing a cardi-
ac pacemaker should therefore consult their physi-
cian before using the machine.
In addition to the operating instructions and the
national and local accident prevention regulations
applicable at the place of use, the acknowledged
technical rules for safe and proper working practices
must be observed.
Apart from the general safety instructions under sec-
tion “Safety“, also the special safety instructions giv-
en under the respective sub-sections must be ad-
hered to.
Any working practices posing a safety risk are pro-
hibited.

GMAK-420, 620 / GMEK-420, 620 Issue 05.2017/Rev. 01 Page 5/20
2.1
Identification of information in the operating
instructions
In these operating instructions, safety instructions
whose non-observance may cause hazards to per-
sons are identified with
Hazard symbol according to DIN 4844 – W 9
for general hazards and with
Hazard symbol according to DIN 4844 – W 8
for electrical hazards.
Safety instructions whose non-observance may
cause damage to the hand extruder and its functions
are marked with
CAUTION
Instructions directly indicated on the hand extruder
must be strictly followed and kept in a fully legible
state.
2.2 Personnel qualification and training
The operating, maintenance and inspection person-
nel must possess appropriate qualification for the
work to be performed. Functional and technical re-
sponsibilities and supervision of the operating per-
sonnel must be clearly regulated by the Operator.
Where the personnel do not have the necessary
skills and knowledge they must be trained and in-
structed (e.g. a DVS basic welder training in extru-
sion welding). A detailed instruction into hand ex-
truder operation will be provided by the Manufactur-
er/Supplier on request. Furthermore, the Operator
has to make sure that the contents of the operating
instructions is fully understood by the operating per-
sonnel.
2.3
Risks resulting from non
-
observance of the
safety instructions
Non-observance of the safety instructions may cause
hazards to persons and the environment or damage
to the hand extruder. Moreover, failure to observe
the safety instructions may lead to the forfeiture of
any damages.
Non-observance of the safety instructions may in
particular involve the following risks:
•failure of important hand extruder functions,
•hazards to persons due to electrical and mechan-
ical impacts including risk of burns,
•hazards to the environment due to vapour-phase
hazardous substances,
•risk of fire.
2.4 Safe working practices
The safety instructions given in these operating in-
structions, the applicable national accident preven-
tion regulations and any existing in-company work
instructions, operating and safety procedures issued
by the Operator must be followed.
2.5 Safety instructions for Operator / operating
personnel
•Before placing the hand extruder in service,
check the mains voltage and frequency against
the data indicated on the type tag. The allowable
tolerances are ± 5 % for voltage and/or ±2 % for
frequency.
•According to VDE 0100 §55, the hand extruder
must be operated via a residual current-operated
circuit breaker or an isolating transformer.
•CAUTION During hand extruder operation (under
load), a voltage of not less than 230 V
1)
must be
available at the connector of the hand extruder.
•When using an extension cable, make sure to
observe the minimum conductor cross-section.
Use extension cables with protective conductor
only.
L
e
ng
th
[m]
Min
imum cross
-
section
[mm²]
up to 19 4.0
1)
20-50 6.0
1)
1) for 230 V AC

Hand Extruder GMAK-420, 620 / GMEK-420, 620
Page 6/20 Issue 05.2017/Rev. 01 MUNSCH Kunststoff-Schweißtechnik GmbH
•Extension cables must be certified for the specific
service conditions (e.g. outdoor service) and
identified accordingly.
Always handle the connecting cable with care.
- Do not kink the connecting cable.
- Do not place any objects on the cable.
- Do not jam or squeeze the connecting cable,
nor pull it over sharp edges.
- Protect the connecting cable from moisture.
•Do not touch the mains connector or con-
necting cable with wet hands. Hold the cable al-
ways at the connector when plugging or unplug-
ging it.
•CAUTION Power generator sets used for power
supply must be designed for the following rated
output:
≥4 x rated output of hand extruder
•Never allow the hand extruder to come into
contact with water: Hazard to persons and
equipment, short-circuit risk.
•CAUTION Never operate the hand extruder
without air supply; risk of hand extruder dam-
age.
When using an external air source, make sure
that the air supply line is adequately dimen-
sioned.
•CAUTION The supply air must be clean, dry and
free from oil and water.
•The hand extruder must not be used in
explosion hazard areas or flammable atmos-
pheres.
Make sure that the hand extruder is firmly posi-
tioned during the extrusion welding job.
The connecting cable, welding rod and hose for
external air supply, if applicable, must be freely
movable and must not obstruct the operator or
third parties in their work.
•Hold and touch the hand extruder only on
the handles provided for this purpose.
- Do not touch bare metal parts (including hot
air hood) either with or without gloves. These
parts reach temperatures of up to 350 °C.
- Attachments may be damaged or impaired
in their function if subjected to the full weight
of the hand extruder.
- Bare metal parts must not come into contact
with other items during the work or work
breaks (e.g. cooling).
D02-0001
•Contact of combustible components
with hot bare metal parts poses a risk of fire!
Do not use synthetic gloves!

GMAK-420, 620 / GMEK-420, 620 Issue 05.2017/Rev. 01 Page 7/20
•Do not direct the hot air jet of the hand extruder
towards living beings or temperature-sensitive
items.
Safety distance: 2 m radius
B ILD D02-0002
•Use suitable personal protection equipment for
overhead work (e.g. hard hat, safety goggles,
gloves, protective clothes …) to guard against
falling items.
•During work breaks and after completion of the
welding job, place the hand extruder on the rests
supplied for this purpose.
CAUTION The hot air hood must be remounted.
Make sure that the hand extruder is firmly
positioned!
Deposit the hand extruder in a dry location.
After completion of the welding job, cool the hand
extruder to safe-to-touch temperature, using the
air supply system.
•Do not operate, dismantle or carry out any
modifications on the hand extruder, if
- the connecting cable or the mains connector
is defective,
- safety devices are damaged,
- foreign matter or liquid has penetrated into the
hand extruder,
- the unit does not work properly or there are
unusual changes in its operating behaviour.
•Never allow the hand extruder to come into
contact with water: Hazard to persons and
equipment, short-circuit risk.
2.6
Safety instructions fo
r maintenance, inspec-
tion and mounting
The Operator is responsible for ensuring that
maintenance, inspection and mounting activities are
performed by authorized and qualified personnel
who are thoroughly familiar with the operating in-
structions.
•As a rule, the hand extruder must be shut off and
the connector unplugged before proceeding to
any work on the unit. The shutoff procedure for
the hand extruder described in the operating in-
structions must be strictly observed.
•Electrical hazards must be ruled out (for details,
see VDE guidelines and the standards of your lo-
cal electric utility, for instance).
•VDE 0701 (IEC 335) prescribes the meas-
urement of the protective conductor resistance,
insulation resistance and leakage current after
each repair or modification to electrical equip-
ment. Furthermore, a visual inspection of the unit
and its connecting cable as well as voltage and
current measurements and a function test must
be carried out.
•Ensure the safe and environmentally compatible
disposal of media, auxiliary materials and re-
placed parts!
•Remount and reactivate all safety and protective
devices immediately on completion of the
maintenance, inspection or repair work.
2.7 Unauthorized modifications and spare parts
Modifications or changes to the unit are only allowed
after consultation with the Manufacturer. In the inter-
est of safety, only original spare parts and accesso-
ries authorized by the Manufacturer should be used.
The use of components other than the original spare
parts may invalidate the Manufacturer’s liability for
any resulting damage.
D02-0002
360°
2m(6ft)

Hand Extruder GMAK-420, 620 / GMEK-420, 620
Page 8/20 Issue 05.2017/Rev. 01 MUNSCH Kunststoff-Schweißtechnik GmbH
3
Transport
a
nd
Storage
3.1 Transport
•Before transport and storage, make
sure that the hand extruder has cooled down
to safe-to-touch temperature.
•Hold and touch the hand extruder only on
the handles provided for this purpose.
Do not touch bare metal parts (including the hot
air hood) – whether with or without gloves – be-
fore having made sure that they are safe to touch.
These parts reach temperatures of up to 350 °C
during operation.
D02-0001
•Always transport or store the hand extruder in
such a way as to preclude any mechanical loads
on the attachments.
If parts have been removed for transport purpos-
es, mount and fasten them carefully before re-
starting the hand extruder!
Transport of the hand extruder in MUNSCH’s
original shipping case is recommended.
3.2 Storage
•Store the hand extruder in a dry and frost-free
place.
•Protect the hand extruder from unauthorized ac-
cess.
•Special preservation is not required.
3.3 Return to Munsch
Should it become necessary to return the hand ex-
truder to MUNSCH Kunststoff-Schweißtechnik
GmbH, always use the original shipping case.
4 Product Description
4.1 Application range
The application range of the hand extruder is defined
by the data on the type tag and the service limits
indicated in these operating instructions.
CAUTION Operation of the hand extruder outside
the service limits stated in these operating instruc-
tions is subject to the Manufacturer’s prior approval.
4.2 General
Type GMEK is a hand extruder with external air sup-
ply.
Type GMAK is a hand extruder with integrated air
supply (Autoair).
For both types of hand extruder, the following pa-
rameters can be freely selected:
- welding rate,
- hot air temperature,
- melt temperature and throughput; the melt
throughput can be controlled downward from the
maximum value, by reducing the speed with the
button of the drive.
CAUTION Too low a speed will cause a risk of drive
overheating!
Driven by a powerful electric motor (1), granulate (2) is fed
into the extruder (3). The screw forces the granulate into
the extruder nozzle, melting it into a homogeneous, com-
pletely plastified mass. As the molten material exits the
extruder nozzle, it is moulded by a welding shoe (4) to the
geometry of the weld seam to be deposited.
Preheating of the base material to be joined is accom-
plished by a preheating nozzle (5) which is supplied from
an integrated hot air unit (6). Air is supplied either from an
external compressor or an on-board blower.

GMAK-420, 620 / GMEK-420, 620 Issue 05.2017/Rev. 01 Page 9/20
Melt and preheat temperatures are controlled sepa-
rately. The setpoint and momentary values are dis-
played concurrently.
The melt temperature must have reached the preset
start interlock temperature for the startup timer to
be activated. After the startup timer has timed out,
the start interlock will be released and the extruder
can be started.
The temperature-controlled start interlock prevents
the drive from starting if there is still unmolten mate-
rial in the extruder, thus precluding damage to the
unit.
The output rate is variable so that the preheat tem-
perature can be matched to the weld thickness.
5 Startup and Shutoff
5.1 General
In addition to the operating instructions and the na-
tional and local accident prevention regulations ap-
plicable at the place of use, the acknowledged
technical rules for safe and proper working practices
must be observed.
Any working practices posing a safety risk are pro-
hibited.
Before starting / shutting off the hand extruder, make
sure to carefully read the instructions under section
“Safety”.
Only trained and qualified personnel may be as-
signed to the operation of the hand extruder.
5.2 Preparation
•Place hand extruder on a firm support and secure
them against toppling over.
•Mount hot air hood
•Only for GMEK hand extruder with external air
supply:
Connect the hand extruder to the external air
source using the hose coupling LW 13 / NM 7.2
provided for this purpose (quick connect-
disconnect); set air rate to 300 l/min at 0.4 bar. A
suitable controller with flow metering function is
recommended for setting the air rate.
CAUTION The supply air must be clean, dry and
free from oil and water.
Never connect an external air source to a
GMAK hand extruder.

Hand Extruder GMAK-420, 620 / GMEK-420, 620
Page 10/20 Issue 05.2017/Rev. 01 MUNSCH Kunststoff-Schweißtechnik GmbH
•Mount welding shoe
- Select the welding shoe required for the
specific weld geometry or machine a welding
shoe blank to the required geometry.
- Observe DVS 2207 Guideline, Part 4 for
machining welding shoe blanks.
- Mount welding shoe to the hand extruder in
the position required for welding.
Observe welding direction!
Tighten set screw (25).
•Mount preheat nozzle
- Select and mount the preheat nozzle (4)
required for the specific weld geometry.
- Observe spacing A = 5 mm.
- Tighten the preheat nozzle using mushroom
head screw (125.22).
Table: Preheat nozzle
Care must be taken to ensure that the preheat
nozzle provides intensive and uniform preheating
(melting) of the base material over the entire joint
width at as low a hot air temperature as possible. For
larger weld seam widths, a wider preheat nozzle is
available as an accessory.
5.3 Starting the hand extruder
Observe section “Safety“.
•CAUTION Never operate the hand extruder with-
out air supply. Otherwise the unit may suffer se-
vere damage.
•CAUTION Before plugging in the mains connect-
or, check that the drive unit is not set to continu-
ous operation.
•CAUTION The hot air hood must be in place.
•CAUTION Start external air supply for GMEK
hand extruder.
•CAUTION Connect the cable between the
Powerbox and the hand extruder.
•CAUTION Plug in mains connector.
•CAUTION In the case of the GMAK hand extrud-
er with integrated air supply, the blower must start
automatically.
•CAUTION Once air exits the preheat nozzle (4),
the heating systems for the air/melt temperatures
may be activated.
•For the operation of the temperature controller,
see section 5.5 “Set temperatures“. For tempera-
ture settings and material-dependent recommen-
dation for the installation of the nozzle and the
compressor nozzle, see page 12.
•The hand extruder will reach its operating
temperature after about 10 to 15 minutes.
•Set the drive speed to maximum and select the
speed on the Powerbox.

GMAK-420, 620 / GMEK-420, 620 Issue 05.2017/Rev. 01 Page 11/20
•Hold and touch the hand extruder only on
the handles provided for this purpose.
D02-0001
•CAUTION The melt temperature must have
reached the preset start interlock temperature
for the startup timer to be activated. After the
startup timer has timed out, the start interlock will
be released and the extruder can be started
.
In addition to the start temperature interlock, the
brushless drive is equipped with a torque control
which prevents the extruder from starting as long
as the operating temperature is not reached
and/or melting of the extrudate is not complete.
5.4 Welding with the hand extruder
Observe section “Safety” and the data sheet.
General
Welding is to be carried out in accordance with the
guidelines of the German Association for Welding
Technology (Deutscher Verband für Schweißtechnik
DVS).
The parts to be joined and the welding rod must be
clean and dry.
5.4.1 Introducing the welding rod
•CAUTION Remove the transparent lid of the
granulate funnel. Fill clean and dry granulate into
the funnel and close the lid. Repeat the proce-
dure before the granulate container has run
down.
5.4.2 Replacement and aging of welding material
•If the welding rod is to be replaced, make sure
that any remaining rod in the hand extruder is
completely removed.
•For this purpose, operate the preheated hand
extruder with the new welding rod until clean new
material discharges.
•The DVS guideline also recommends this proce-
dure for hand extruders which have been out of
service for prolonged periods while still being
filled with welding rod.
•Ensure safe and environmentally compati-
ble disposal of any waste generated!
5.4.3 Welding direction / rate
•The pressure of the discharging extrudate causes
the welding shoe (and hence, the hand extruder)
to move in welding direction.
•See DVS Guidelines for the welding rate.
D02-0026
5.4.4 Interruption of work
•Observe section “Safety“.
Do not leave the hand extruder unattended.
Make sure to maintain the air supply.
•When interrupting the welding job, switch off the
drive unit and deposit the hand extruder as
shown in the illustration below.

Hand Extruder GMAK-420, 620 / GMEK-420, 620
Page 12/20 Issue 05.2017/Rev. 01 MUNSCH Kunststoff-Schweißtechnik GmbH
5.4.5
Shutoff
Observe section “Safety”.
•After completion of the welding job, switch off
the drive unit and deposit the hand extruder as
shown in the illustration (see preceding section).
Do not leave the hand extruder unattended.
5.4.5.1 Hand extruder with integrated air supply,
type GMAK
•Press “return“ button once to switch off the heat-
ing circuits.
Maintain the air supply of the hand extruder
until the unit has completely cooled down!
•Pull mains connector.
5.4.5.2 Hand extruder with external air supply,
type GMEK
•Press “return“ button once to switch off the heat-
ing circuits.
•Pull mains connector.
Maintain the air supply of the hand extruder
until the unit has completely cooled down!
Never use water or another coolant to
accelerate the cooling process!
5.4.6 Transport/Storage
Make sure to observe the instructions under section
“Transport/Storage“.
5.5 Set temperatures and material-dependent
recommendation, for the installation of the
nozzle and compression nozzle
The default settings for the melt and air temperatures
of the GMEK and GMAK hand extruders are shown
in the following temperature chart.
(The values have been determined with the aid of
reference materials.)
Temperature chart for GMEK / GMAK
Material
M
elt temperature
Air temperature
PP 200 – 240 °C 250 – 300 °C
PE 200 – 240 °C 250 – 300 °C
PVDF 240 – 260 °C 280 – 350° C
If other temperatures are needed the corresponding
settings can be made on the temperature controller.
Recommendation for nozzle and compression
nozzle
GMAK/GMEK-420
Material
Nozzle
Co
mpression nozzle
PP 8 8 / 2
PE 4 6 / 05
Dowlex 4 8 / 1
GMAK/GMEK-620
Material
Nozzle
Compression nozzle
PP 8 8 / 375
PE 5 8 / 05
Depending on the material and manufacturer of the
granulate, other combinations are also conceivable.
•CAUTION Left-hand thread.
Change the two parts in the heated state.
•CAUTION Risk of burns.
Set temperatures

GMAK-420, 620 / GMEK-420, 620 Issue 05.2017/Rev. 01 Page 13/20

Hand Extruder GMAK-420, 620 / GMEK-420, 620
Page 14/20 Issue 05.2017/Rev. 01 MUNSCH Kunststoff-Schweißtechnik GmbH
6
Main
tena
n
ce/Inspection
Pull mains connector before carrying out any
maintenance and repair work on the hand extruder.
Maintenance and repair work on electrical tools may
only be carried out by qualified electricians.
The hand extruder together with the hot air
hood must have cooled down to safe-to-touch tem-
perature.
Observe the instructions under section “Safety“.
Maintenance and repair work may only be carried
out by qualified personnel or by our service staff.
To ensure the proper function of the hand extruder
over its entire service life for its intended service, we
recommend:
- to have all maintenance, inspection and mounting
work carried out by authorized and qualified per-
sonnel who are familiar with the operating instruc-
tions,
- to always shut off the unit before carrying out any
work on it,
- to remount and reactivate all safety and protec-
tive devices immediately after completion of the
maintenance/repair work.
During maintenance and repair work, make sure that
the hand extruder and its individual components are
firmly positioned.
In addition to the operating instructions and the na-
tional and local accident prevention regulations ap-
plicable at the place of use, the acknowledged tech-
nical rules for safe and proper working practices
must be observed.
Any working practices posing a safety risk are pro-
hibited.
Activities other than those described in this
section may only be performed at the Manufacturer’s
workshops!
6.1 Maintenance/inspection of GMEK/GMAK
hand extruder
•CAUTION After approx. 500 operating hours, the
hand extruder including drive unit must be
thoroughly cleaned and inspected. This work may
only be carried out at the manufacturer’s work-
shops.
•CAUTION Cables, switches, plug-in connections
must be inspected by qualified staff every three
months (requirement according to VBG4); the in-
spection results must be documented.
6.2 Dismantling
Prior to dismantling the hand extruder, pull the mains
connector.
The hand extruder must be at ambient temperature.
Damaged power cables and/or connecting cables
(between the Powerbox and the hand extruder) must
be completely replaced. “Mended” cables pose a
hazard to life and limb. Cable replacement is to be
carried out by qualified electricians only.
The safety precautions described under sections
“Safety“ and “Malfunctions, Causes and Remedies“
must be strictly adhered to.
6.2.1 Overview of spare parts/attachments
When ordering spare parts, always indicate the
serial number of the extruder.
Make sure to use original spare parts only.
For spare parts supply, contact MUNSCH Kunststoff-
Schweißtechnik GmbH.
----------------------------------------------------------------------
Extruder screw bearing:
K03701 = Axial bearing (replace)
K03702 = Ball bearing (replace)
K03703 = Circlip (replace, if required)
K03704 = Seal ring (replace)
K04080 = Spacer ring (replace, if required)
----------------------------------------------------------------------

GMAK-420, 620 / GMEK-420, 620 Issue 05.2017/Rev. 01 Page 15/20
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Hand Extruder GMAK-420, 620 / GMEK-420, 620
Page 16/20 Issue 05.2017/Rev. 01 MUNSCH Kunststoff-Schweißtechnik GmbH
7 Malfunctions, Causes and Remedies
7.1 Trouble-shooting
The following table lists potential operating upsets of
the hand extruder, possible causes and their reme-
dies (fault diagnosis chart).
Should malfunctions occur which are not covered
here or which cannot be traced back to the cause
stated, please contact MUNSCH Kunststoff-
Schweißtechnik GmbH.
Malfunction Fault No.
Drive motor does not start 5, 8, 9, 10, 11, 12, 14, 15, 16, 17, 18, 19, 23
Drive motor switches off 5, 8, 9, 10, 11, 12, 14, 15, 16, 17, 18, 19, 23
No granulate feeding 16, 17
No extrudate conveyed out of welding shoe 16
Extrudate output decreases during operation 14, 16
No air supply 6, 7, 13
Integrated air supply without function 5, 22
No hot air 2, 3, 4, 5, 6, 18, 22
Hot air temperature below setpoint temperature 2, 3, 4, 8, 10, 18, 22, 14
Melt temperature below setpoint temperature 2, 3, 9, 11, 14
Extruder does not heat up 2, 3, 12, 22
Temperature above preset range 2, 3, 18, 19
Controller fault signal: E 2
Controller fault signal: OEAIR 2, 13, 22
Controller signal: OFF 9, 10, 11, 12
Control fluctuates 3, 13,19,12
7.2 Fault diagnosis
Fault
No. Possible causes Remedies
2 Temperature sensor defective
1)
3 Temperature controller defective
1)
4 Air rate too high Reduce air rate to specified level
3)
5 Cable connections defective Check cable connections
1)
6 External air supply not connected
3)
Connect external air supply
7 External air supply without function
3)
Switch on external air supply
Check the external air supply system for malfunc-
tions using the separate manual, or have it checked.
8 Hot air temperature below start interlock tem-
perature Allow hand extruder to heat up
Air rate too high →reduce air rate
3)
1) Consult MUNSCH Kunststoff-Schweißtechnik GmbH
2) Only for GMAK
3) Only for GMEK

GMAK-420, 620 / GMEK-420, 620 Issue 05.2017/Rev. 01 Page 17/20
Fault
No. Possible causes Remedies
9 Melt temperature below start interlock temper-
ature Allow hand extruder to heat up
10 Preheat time for hot air too short Allow hand extruder to heat up
11 Preheat time for melt too short Allow hand extruder to heat up
12 Heating cartridge defective
1)
13 Air supply not constant
- External air supply:
- Check air supply unit
3)
- Integrated air supply:
1)
14 Wrong rated voltage Rated voltage > >>
>permissible voltage
Check mains voltage
Rated voltage <
<<
<permissible voltage
Check mains voltage
1)
15 Extension cable heats up
- Unroll cable reel
- Check cable cross-section (see also section
“Safety“)
16 Extruder nozzle plugged with foreign matter Clean extruder.
Extruder nozzle – left-hand thread
17 Drive unit defective
1)
18 Electronic control defective
1)
19 Controller programming error
1)
22 Hot air unit defective
1)
23 No mains voltage Check voltage supply
1) Consult MUNSCH Kunststoff-Schweißtechnik GmbH
2) Only for GMAK
3) Only for GMEK

Hand Extruder GMAK-420, 620 / GMEK-420, 620
Page 18/20 Issue 05.2017/Rev. 01 MUNSCH Kunststoff-Schweißtechnik GmbH
8 Technical Data
Type designation GMAK-420 / GMEK-420 GMAK-620 / GMEK-620
Welding materials PP, PE, PVDF and other materials after
tests or consultation with company
Munsch
PP, PE, PVDF and other materials after
tests or consultation with company
Munsch
Welding rate, approx. 1,8 – 5,0 kg/h / depending on granulate
type and size
Application range Wall thicknesses 10-40 mm and
film/sheeting welds
Weight 12,8 kg
Drive 230 V AC with speed control 230 V AC with speed control
Extruder heating system 650 W 800 W
Air preheater 2300 W 2300 W
Air supply GMAK = integrated GMAK = integrated
Air rate GMEK = 300 l/min at 0.4 bar GMEK = 300 l/min at 0.4 bar
Control of melt tempera-
ture Temperature controller with concurrent
momentary value and setpoint display Temperature controller with concurrent momentary value and setpoint display
Control of air tempera-
ture Temperature controller with concurrent
momentary value and setpoint display Temperature controller with concurrent momentary value and setpoint display
Cold start protection Start temperature interlock and startup
timer for melt and preheat air Start temperature interlock and startup timer for melt and preheat air

GMAK-420, 620 / GMEK-420, 620 Issue 05.2017/Rev. 01 Page 19/20
Warranty Certificate
..............................................................................................................
..............................................................................................................
..............................................................................................................
Name and address of Purchaser
Type of unit: Hand extruder
Type designation:
Serial No.:
P.O. No.:
Your warranty
MUNSCH Kunststoff-Schweißtechnik GmbH hereby war-
rants the unit to be free from defects in materials and
workmanship from the date of its first acquisition. Should
deficiencies resulting from defects in materials or work-
manship be identified during the warranty period, the
dealers will, in accordance with the following terms and
conditions, repair the unit or, at their discretion, replace
either the complete unit or the defective components
without charging labour or material costs.
..............................................................................................................
Dealer’s stamp and signature

Hand Extruder GMAK-420, 620 / GMEK-420, 620
Page 20/20 Issue 05.2017/Rev. 01 MUNSCH Kunststoff-Schweißtechnik GmbH
Warranty
1 The Manufacturer warrants freedom from defects
in materials and workmanship and state-of-the-
art performance of the purchased article for a pe-
riod of six (6) months from the date of delivery.
2 The Purchaser shall check the article delivered
for completeness and freedom from defects im-
mediately after receipt.
3 The Purchaser shall be entitled to the making
good of defects and any resulting damage to
other parts of the purchased article (remedial
work).
The procedure for claims under this warranty
shall be as follows:
3.1 The Purchaser may assert claims under this
warranty either with his dealer or with a company
authorized by the Manufacturer to provide ser-
vices for the purchased article. The Purchaser
shall give written notice of defects to the respec-
tive company promptly after such defects have
been identified or shall have such defects regis-
tered by the respective company.
3.2 Defects shall be promptly remedied in accord-
ance with the technical requirements by either
replacement or repair of the defective parts, the
cost of the remedial work being for the account
of the Manufacturer. Replaced parts shall be-
come the property of the Manufacturer.
If, as a result of the remedial work, additional
maintenance measures are prescribed by the
Manufacturer, the resulting costs including the
costs of materials and lubricants shall be for the
Manufacturer’s account.
3.3 For replacement parts installed within the scope
of the remedial work, a warranty will be provided
under the purchase contract, the warranty period
for such parts ending on expiry of the warranty
period of the object purchased.
3.4 For the warranty to become effective, this war-
ranty certificate must be produced for each re-
pair.
4 If the defect cannot be remedied or if the Pur-
chaser cannot be reasonably expected to accept
any further attempts at making good the defect,
the Purchaser may demand annulment (cancella-
tion of the contract) or a price reduction (reduc-
tion of compensation) in lieu of remedial work. In
such a case, the Purchaser shall not be entitled
to any replacement.
5 Manufacturer’s warranty obligations shall not be
affected by a change in ownership of the pur-
chased article.
6 Any damage incurred through the following acts
or omissions of Purchaser shall be expressly
excluded from this warranty:
6.1 Purchaser’s failure to report a defect pursuant to
subsection 3.1 or to promptly provide an oppor-
tunity to remedy the defect following Manufactur-
er’s request, or
6.2 improper handling or overload operation of the
purchased article, or
6.3 prior repair, maintenance and servicing of the
purchased article by a company not authorized
by the Manufacturer, if the Purchaser can be
reasonable expected to have known that such
company was not authorized, or
6.4 the installation of parts into the purchased article
without having obtained Manufacturer’s prior ap-
proval for such parts or the modification of the
purchased article in a way not approved by the
Manufacturer, or
6.5 Purchaser’s failure to observe the instructions
given in the user’s manual accompanying the
purchased article (e.g. operation, maintenance
and care), or
6.6 Purchaser having removed the serial number or
made it illegible.
7 Natural wear and tear shall be expressly exclud-
ed from this warranty.
8 Accidents, force majeure or other circumstances
beyond the control of the Manufacturer, in partic-
ular damage caused by lightning, overvoltage,
water, fire, etc. shall be excluded from this war-
ranty.
9 All rights under this warranty shall become null
and void on expiry of the warranty term pursuant
to Section 1. For claims asserted within the war-
ranty term but no settled by its expiry, the war-
ranty shall remain effective until the respective
defect has been remedied. The period of limita-
tion shall be suspended for such claim.
MUNSCH Kunststoff
-
Schweißtechnik GmbH
Im Staudchen •D-56235 Ransbach-Baumbach
P.O. Box 142 •D-56221 Ransbach-Baumbach
Germany
Phone: [phone]
Telefax: [phone]
Internet: http://www.munschwelding.com
E-Mail: [e-mail]