Munsch K01405B User manual

Page 1/16 Ausgabe 08.2013/Rev.00 MUNSCH Kunststoff-Schweißtechnik GmbH
Type:
Weld trimmer
Code:
K01405B
Betriebsanleitung
Operating instructions
MUNSCH Kunststoff-Schweißtechnik GmbH
Im Staudchen • D-56235 Ransbach-Baumbach
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
http://www.munschwelding.com
Firmensitz/Registered Office: Im Staudchen, D-56235 Ransbach-Baumbach
Registergericht/Registration Court: Amtsgericht Montabaur, HRB 3959
Geschäftsführer/Managing Director: Stefan Munsch

MUNSCH Kunststoff-Schweißtechnik GmbH Ausgabe 08.2013/Rev.00 Page 2/16
Hinweis: Diese Betriebsanleitung muss dem Bedienungspersonal jederzeit zur Verfügung
stehen. Lesen Sie die vorliegende Betriebsanleitung vor Inbetriebnahme des
Gerätes sorgfältig durch.
Note: These operating instructions must always be available to the machine operators. Make
sure to read them carefully before placing the unit in service.
Index
Foreword...................................................................................................................................................4
Hazards resulting from non-observance of the safety instructions.......................................................5
Safety ........................................................................................................................................................6
General..................................................................................................................................................6
Intended use ..........................................................................................................................................6
Organizational measures.......................................................................................................................6
Personnel selection and qualification....................................................................................................7
Safety instructions on specific Operating phases..................................................................................7
Safety equipment...................................................................................................................................7
Instructions on specific types of danger................................................................................................7
Taking a break / End of work................................................................................................................8
Devices usable in different locations....................................................................................................8
Accessories/Replacement parts.............................................................................................................9
Product description ...................................................................................................................................9
General..................................................................................................................................................9
Inspection..............................................................................................................................................9
Commissioning / De-commissioning......................................................................................................10
General................................................................................................................................................10
Completion of the Weld trimmer........................................................................................................10
Incommissioning.................................................................................................................................10
Maintenance............................................................................................................................................12
General................................................................................................................................................12
Maintenance / Inspection ....................................................................................................................12
Regular maintenance...........................................................................................................................13
Fault finding............................................................................................................................................13
Fault finding........................................................................................................................................13
Transport / Storage..................................................................................................................................14
Safety instructions...............................................................................................................................14
Storage conditions...............................................................................................................................14
Transport to MUNSCH.......................................................................................................................14
Conservation .......................................................................................................................................14
Parts list...................................................................................................................................................16

Page 3/16 Ausgabe 08.2013/Rev.00 MUNSCH Kunststoff-Schweißtechnik GmbH
Konformitätserklärung des Herstellers
nach der EG-Maschinenrichtlinie 2006/42/EG Anhang II, Nr. 1 A
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
hereby declares on its own behalf and responsibility that the weld trimmer unit to which this
declaration refers, conforms to the following standards, codes or regulations:
Directive 2006/42/EC
Directive 89/336/EC
EN 61029-1
VDE 0701 Part 1
VDE 0702 Part 1
EN 50144
Directive 73/23/EC
EN 60204-1
EN 61029-1
Conformance of the product with the above standards is subject to the condition that it is used in
accordance with the contractually agreed service conditions, the responsibility for which shall rest with
the user.
Modifications to the machine/unit or the use of the machine/unit for applications other than the
intended service will make this declaration null and void, unless expressly approved in writing by the
manufacturer.
Ransbach-Baumbach, März 2013 Dipl.-Ing. Stefan Munsch
Managing director

MUNSCH Kunststoff-Schweißtechnik GmbH Ausgabe 08.2013/Rev.00 Page 4/16
Foreword
This instruction handbook should help you to become familiar with the Weld trimmer and to use
its intended application possibilities.
The instruction handbook contains important information on safety, proper and economic operation
of the Weld trimmer. Observing these instructions will help prevent hazards, reduce repair costs and
non-productive times and increase the reliability as well as the life limit of the Weld trimmer.
The instruction handbook must always be available at the location where the Weld trimmer is in use.
The instruction handbook must be read and used by anyone who has been appointed to work with/on
the Weld trimmer, for example, during
Assembly
operation
maintenance (service, ...) and / or
transport.
Specially trained personnel must be used for operation and maintenance of the Weld trimmer.
Apart from the instruction handbook and those obligatory regulations for accident prevention applic-
able in the country of use and application location, the standard technical regulations for safe and
professional operation must be observed.
This instruction book contains basic information which must be observed during installation, oper-
ation and maintenance. For this reason, this instruction book must be read by the mechanic as well
as the responsible specialist personnel/user before assembly and initial operation and must al-ways
be available at the location where the Weld trimmer is in use.
Not only the general safety instructions listed in the chapter on "Safety" but also the special safety
instructions added to the other main points must be observed.
Safety symbol according to DIN 4844-W9
Safety symbol according to DIN 4844-W8
gCautiong
Danger for functions
Use of special tools
Instructions attached to the Weld trimmer such as, e.g.,
warning plate
rating plate
must be observed and must always be clearly visible.

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Hazards resulting from non-observance of the safety instructions
Non-observance of the safety instructions may lead to hazards to personnel as well as the environment and
device.
Non-observance of the safety instructions may lead to the loss of any claims for damages.
Non-observance of the safety instructions may lead in particular to the following hazards, for example:
Failure of important Weld trimmer functions
Failure of specified methods for care and maintenance
Personal hazard due to electrical and mechanical influences.
MUNSCH Kunststoff-Schweißtechnik GmbH strives to keep not only its products but also the relevant
documentation up to date and to describe these as clearly as possible for the user.
If you have any suggestions for improving our documentation, we would be pleased to hear from you.
Please let us know your suggestions.

MUNSCH Kunststoff-Schweißtechnik GmbH Ausgabe 08.2013/Rev.00 Page 6/16
Safety
General
The general agreement concerning safety regulations in the VDE 0701 standard applies analogously.
The operation of Weld trimmers is subject to the applicable national regulations.
Apart from the instruction book and the obligatory regulations for accident prevention applicable in the
country of use and application location, the technical regulations for safe and professional operation
must be observed. Guideline 92/57/EWG of 24.06.1992 applies analogously.
Not only the general safety instructions listed in this chapter but also the special safety instructions
added to the other main points must be observed.
Do not attempt any operation which may be a safety hazard.
Intended use
The Weld trimmer has been constructed according to the latest technology and safety regulations.
However, improper use may lead to hazards for the user or a third party or damage to the machine and
other material assets.
The Weld trimmer must only be used if it is in excellent technical condition. Use the Weld trimmer
according to regulations and be aware of safety and hazards described in the instruction handbook.
If the Weld trimmer fails to function correctly, stop work immediately and secure! Mal-functions
should be eliminated (or have them eliminated) straightaway.
The Weld trimmer is only to be used as agreed in the order confirmation. Another use or use beyond
this is not as intended. The manufacturer/supplier is not liable for damages resulting from this. The
user is solely responsible. Intended use involves observance of the instruction hand-book and keeping
to the inspection and maintenance conditions.
If a new application of the Weld trimmer lies outside the limits of use defined in the order
confirmation or if the user is in doubt regarding changes, the change must be approved by the
manufacturer/supplier.
Organizational measures
Always keep the instruction handbook ready to hand at the location where the Weld trimmer is in use.
Observe the general, legal, national and other compulsory regulations on accident prevention and
environmental protection in addition to those described in the instruction handbook.
The individual appointed to undertake work using the device must have read the instruction hand-book
before start working, paying particular attention to the chapter on safety instructions.
If changes are made to the Weld trimmer or its operating performance relevant to safety, stop working
with the Weld trimmer immediately and report the malfunctions to the authority/person responsible.
Do not undertake any changes on, add to or reconvert the Weld trimmer which could impair safety,
without permission from the supplier.

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Personnel selection and qualification
Work on electrical parts of the Weld trimmer may only be undertaken by skilled electricians or by
persons instructed under direction and supervision of a skilled electrician according to electrotechnical
regulations.
Only specially trained personnel may be used for the assembly, operation and maintenance of the Weld
trimmer.
Safety instructions on specific Operating phases
Observe the specified adjustment, maintenance and inspection activities and deadlines including in-
formation on parts/part equipment in the instruction handbook. These activities may only be carried
out by trained personnel.
Individual parts and larger components must be se-cured carefully when being exchanged so that they
do not cause any hazard.
Before cleaning the Weld trimmer, cover/glue up all openings into which a cleaning agent must not
penetrate due to safety and/or functioning reasons (e. g. electro motors).
After cleaning, completely remove the covers/glue.
Always tighten screw connections loosened during maintenance and repair work.
If safety devices have to be removed during set-up, maintenance and repair, these must be reassembled
and inspected once the maintenance and repair work has been concluded.
According to VDE 0701 (IEC 335), it is stipulated, that the protective resistor, insulation resistance
and the current earth leakage must be measured after every maintenance or change. In addition a visual
inspection of the connecting cable, a voltage and electric charge measurement and a functional check
must be carried out.
Make sure process materials as well as replacements parts are disposed of safely and with con-
sideration to the environment.
Safety equipment
Personally safety equipment (gloves and protection glasses) are required for working with the weld
trimmer.
Instructions on specific types of danger
Contact
The weld trimmer may only be held and touched on the handles intended.
The Weld trimmer has to be held fixed with both hands
The yellow button of the locking device should only be pressed if the machine is out of operation.
The safety cover of the Weld trimmer may only be opened for cleaning- and maintenance
purposes, when the machine is not running and the mains plug is pulled out.
During operation objects may not get near the opening of the Weld trimmer, because this can lead
to danger for human being and machine.

MUNSCH Kunststoff-Schweißtechnik GmbH Ausgabe 08.2013/Rev.00 Page 8/16
Working area
The working area of the Weld trimmer should be clean and free from objects. The weld seams should
be cured.
Operation
Before connecting to the mains, check the rated voltage of the Weld trimmer.
The mains voltage must correspond to the rated voltage on the Weld trimmer’s rating plate.
When using an extension cable, be aware of the minimum cross section of the cables.
Length [m]
Cross section [mm²]
Up to 19
2,51)
4,02)
20 –50
4,01)
6,02)
1) with 230 Vac. Voltage
2) with 110 Vac. voltage
The extension cable must be permitted for the application location (e.g. outdoors) and marked accordingly.
Always take care when handling the connecting cable.
Make sure the connecting cable does not have any kinks.
Do not place any object on the connecting cable.
Do not clamp or squash the connecting cable.
Do not touch plug and connecting cable with wet hands. When plugging in and out, you may only held the
connecting cable at the connector.
Never continue using the Weld trimmer, take it apart or make any changes yourself if
The connecting cable or the plug of the Weld trimmer is damaged.
The safety devices are damaged.
A foreign body or fluid has penetrated the inside of the Weld trimmer.
The device is not functioning normally.
Unusual changes occur in the operating status.
Never splash the Weld trimmer with water: risk of personal injury, short circuit
The Weld trimmer must not be used in a potentially explosive or inflammable environment.
Make sure you are in a stable standing position when operating the Weld trimmer
The connecting cable must be able to move freely and not be hindered by the user or a third party
during operation.
Taking a break / End of work
Take care that the cutter head’s safety cover is closing automatically, when taking a break or end of
work.
Plug off the mains, to avoid an unintentional commissioning.
Devices usable in different locations
Reassemble the parts which had to be dismantled for transport purposes and secure before continuing
operation.
When putting into operation again, proceed according to the instruction handbook.

Page 9/16 Ausgabe 08.2013/Rev.00 MUNSCH Kunststoff-Schweißtechnik GmbH
Accessories/Replacement parts
Only those products approved by MUNSCH may be used as spare-parts. The manufacturer is not liable
for any damages which arise from using products and accessories not approved.
Conversion or change of the Weld trimmer is only permitted after consultation with the manufacturer.
The replacement parts and authorized accessories approved by the manufacturer serve safety purposes.
Use of other parts can cancel the liability for the consequences resulting.
Product description
General
The Weld trimmer is equipped with a speed-controlled, motor. The on/off switch is a slide switch with
a fast unlocking device operated by pressure on the back end of the slide switch.
The Welding trimmer consists of a strong motor and a cutter head, which is flanged on the angular
gear. The cutter head has a safety cover, which opens only during operation to release the cutter
knives.
The safety cover is opened by two rubber feet, which is mounted on the cutter head. It will open when
the Weld trimmer is placed on the work piece and is moved in working direction.
The Weld trimmer consists of a fixed housing with two slide discs. Inside the housing the cutter head
rotates with four knives. The cutter head rotates against working direction.
A constant attack on the working piece is warranted by the arrangement of the knives.
If the performance of the Weld trimmer is definitely decreasing, the cutter knives have to be replaced.
The cutter knives have two cutting edges and can be turned once.
See chapter maintenance.
The plating of the machine on the working place by the glide discs enables working without any difficulties,
also on curved surfaces.
Inspection
All MUNSCH Weld trimmers are subject to extensive performance inspection before delivery. Only
aggregates in perfect technical condition leave the factory.
By observing this instruction handbook and the agreed operating conditions trouble-free operation is
guaranteed.

MUNSCH Kunststoff-Schweißtechnik GmbH Ausgabe 08.2013/Rev.00 Page 10/16
Commissioning / De-commissioning
General
Beside the instruction handbook and the obliging regulations for accident prevention in the country
and place of usage the standard technical regulations for safety- and professional working are also to
consider.
Every safety endangering working procedure is to be avoided.
Please read thoroughly through the chapter safety before starting commissioning/de-commissioning.
The use of trained experts is required for the commissioning and de-commissioning of the Weld
trimmer.
Completion of the Weld trimmer
The mains plug should not be plugged in.
Mount the handle
- Put the Weld trimmer in a stable position
- Put on the handle (K02941) and screw up tightly clockwise. Tighten it with a screw-wrench.
The handle may not loosen itself
Incommissioning
Preparations
Prior working steps:
Completion of the Weld trimmer
Commissioning of the Weld trimmer
Observe chapter safety.
gCautiong
The Weld trimmer has to be switched off and the mains plug has to be
plugged out.
After opening the safety cover, please check if the cutter head is
running properly, no objects are clamped and all cutter knives are
mounted correctly.
Please make sure, if the drive is not switched on before putting in the
mains plug.
Have the Weld trimmer in your hands and put in the mains plug.
The machine may only be held and touched on the handles intended.
You engage the machine by pressing the on / off switch.
The Weld trimmer is to put with the rubber feet at the housing
downwards on the weld seam. The weld seam should be in the middle
of the rubber feet.
The safety cover is opened by moving the machine in working
direction and the cutter head can be put on the weld seam.
Traction occurs against working direction during operation.
Please put the Weld trimmer only on the weld seam, if the machine is
switched on.
Handles
Milling direction
Main switch

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Milling direction / speed
The milling direction (working direction) is towards the user, this
means in direction of the power line.
The milling speed depends on the level of the weld seam bead and also
on the adjusted speed. The surface, which is milled, has to be even. If
the surface is not even, the milling speed should be adjusted or the
revolution should be increased
Taking a break
Observe the chapter on safety.
If you take a break from milling, the drive device must be switched off and the Weld trimmer placed in
a secure position.
The machine is switched off by pressing on the back part of the fast releasing device of the on/off
switch.
After switching off, the machine is running 5 seconds further.
Do not leave the Weld trimmer unattended.
De-commissioning
Observe the chapter on safety.
When finish milling, the driving device must be switched off and the Weld trimmer placed in a secure
position.
The machine is switched off, when pressing on the back part of the fast releasing device’s on/off
switch.
After switching off, the machine is running 5 seconds further.
Do not leave the Weld trimmer unattended.
Transport / Storage
Observe the chapter transport and storage.
Speed control

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Maintenance
General
Before carrying out any maintenance work on the device, pull out the mains plug!
Maintenance work on electric tools may only be carried out by skilled electricians
The Weld trimmer must be cool enough to touch.
Observe the chapter on Safety.
Maintenance work may only be carried out by suitable specialist personnel or by our customer
services' employees.
To make sure that the Weld trimmers will function safely during their life within their intended use, we
recommend:
All maintenance, inspection and assembly work must be executed by authorized and qualified
specialist personnel who have gained sufficient knowledge by reading the instruction handbook
thoroughly.
All work has to be executed when the device is at a standstill.
Directly after concluding any work all safety and protection devices have to be attached again
and/or made functional.
During maintenance, make sure that the Weld trimmer and/or its individual parts is/are stable.
Apart from the instruction handbook and the obligatory regulations for accident prevention applicable
in the country of use and application location, the standard technical regulations for safe and profes-
sional operation must be observed.
Do not attempt any operation which may be a safety hazard.
Activities not mentioned here may only be carried out by the manufacturer!
Maintenance / Inspection
Motor
If a motor cleansing is necessary, blow out the motor housing through the air slots on the back. This
may only be carried out by a skilled electrician.
Carbon brushes
The carbon brushes of the drive may only be checked and changed, if applicable, by a skilled
electrician.
Observe the chapter on Accessories/Replacement parts.
Cutter head
Maintenance works may only be carried out, if the machine is not running any more and the mains
plug is pulled out.
gCautiong
Please do always change / turn over all four knives at the cutter head.
The knives of the cutter head preheat during operation and may only be changed, if the machine is
already cooled down.
Please proceed following these steps:
Open the cutter head’s safety cover.
Turn the cutter head to the respective knife
Open both hexagon socket screws of the knife.
Take out the knife and check the grade of abrasion.
Also check the other knives.
All four cutter knives have to be replaced at all times.
Fasten the new / turned knives.
Close the cutter head’s safety cover.
Fitting position of
the knives

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Mains connection cable
If the mains connection cable is defective, it has to be changed completely.
Patched cables are life-threatening.
According to VDE 0701 (IC 335), it is required to measure the protective resistance, the insulating
resistance and the current leakage of all electrical tools after every repair or change. In addition, a
visual examination of the connection cable, a tension measurement and a power measurement is to be
done.
Pull out the mains plug first!
This work may only be carried out by a skilled electrician.
Regular maintenance
The Weld trimmer is extensively insensible against fouling.
However, it is recommended to clean the Weld trimmer after every use.
Do not use caustic cleansing agents!
If removing tenacious dirt, please take care that the Weld trimmer, especially the connection cable, is
not damaged.
Fault finding
Fault finding
The following table contains malfunctions which may occur on the Weld trimmer and information on the
possible causes and how to remove them (Fault diagnosis table).
If malfunctions occur which are not mentioned here or if the malfunctions do not lead back to the cause
specified, please contact MUNSCH Kunststoff-Schweißtechnik GmbH.
Malfunction
Error no.
Drive motor does not start
1, 2, 3, 4, 5, 6, 7
Drive motor switches off
1, 2, 4, 5, 6, 7
Motor rotation speed varies
5, 6, 9, 10
The milling result is dissatisfactory
8, 9, 10
Fault-no.
Possible cause
Corrective action
1
Cable connections defective
Check cable connections1)
2
No power supply
Produce power supply
3
Nominal voltage > permissible voltage
Do not use the Weld trimmer any
more and check acc. To VDE 0701,
or send to MUNSCH Kunststoff-
Schweißtechnik GmbH
4
Extension cable heats up
-Unroll the cable reel.
-Check the cable cross section (see
also chapter on Safety)
5
Defect in the driving device
1)
6
Carbon brushes of the driving motor defective
Observe the instructions in the
Maintenance and Safety chapter
Exchange the carbon brushes
See chapter Maintenance
7
Cutter head is blocked by objects
Observe the instructions in the
Maintenance and Safety chapter!
Remove object in the cutter head.
Check, if the cutter knives are not
damaged and are in tightly.

MUNSCH Kunststoff-Schweißtechnik GmbH Ausgabe 08.2013/Rev.00 Page 14/16
Fault-no.
Possible cause
Corrective action
8
Cutter knives are used up
Observe the instructions in the
Maintenance and Safety chapter!
Change the cutter knives.
See chapter Maintenance
9
The fitting position of the cutter knives is not
correct
Observe the instructions in the
Maintenance and Safety chapter!
Mount the cutter knives in the right
fitting position.
See chapter Maintenance.
10
Feed rate too high, or speed too low
Reduce the feed rate or raise the
speed.
See chapter Commissioning / De-
Commissioning
Transport / Storage
Safety instructions
Observe the chapter on Safety.
For transport / storage, the Weld trimmer must have cooled down so that it’s maximum hand-hot.
Contact
The weld trimmer may only be held and touched on the handles intended.
Storage conditions
Keep away unauthorized people.
Store it in a dry place.
Transport to MUNSCH
If it is necessary to send the Weld trimmer to MUNSCH Kunststoff-Schweißtechnik GmbH use the
original packing.
Please include a description of the fault, to make possible a quick fault cause finding.
Conservation
A special conservation is not necessary.

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Mounting
Is the casing basement mounted the distance dimension 4,5 ± 0,2 has to be
controlled with a depth gauge.
As a help for mounting use 2 Hexagon socket head cap screws M5x40.

MUNSCH Kunststoff-Schweißtechnik GmbH Ausgabe 08.2013/Rev.00 Page 16/16
Parts list