GMax V5.2 EN

OPERATION and INSTALLATION MANUAL
Conventional blade granulators G-Max 12 - 23 – 33
Beside-The-Press applications
G-Max-V5.2-EN Operation and Installation Manual

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How to use this manual
 Use this manual as a guide and reference for installing, operating and maintaining your granulator.
The purpose is to assist you in applying efficient, proven techniques that enhance equipment
productivity.
 This manual covers only light corrective maintenance.
No other maintenance should be undertaken without first contacting a Wittmann service centre.
 The functional description section outlines models covered, standard features and safety features.
Additional sections within the manual provide instructions for installation, pre-operational procedures,
operation, preventive and corrective maintenance.
 The installation chapter includes required data for receiving, unpacking, inspecting and setup of the
granulator.
We can also provide the assistance of a factory-trained technician to help train your operator(s) for a
nominal charge.
This section includes instructions, checks and adjustments that should be followed before
commencing with operation of the granulator.
 The operation chapter includes a description of electrical and mechanical controls, in addition to
information for operating the granulator safely and efficiently.
 The maintenance chapter is intended to serve as a source of detailed assembly and disassembly
instructions for those areas of the equipment requiring service.
 A preventive maintenance section is included to ensure your granulator provides excellent, long
service.
 The troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
 Wear and spare parts are listed with their corresponding item numbers for each specific granulator
in this manual. Another list of part kits and options that can be mounted on the granulator is also
contained in another chapter. Refer to this section for ordering the parts you need. Have your serial
number and model number ready when ordering.
 You find on the CD provided with this manual:
- Instructions for using the operators console.
- Wiring diagrams of the granulators.
- For your technical assistance needs we add a listing of our worldwide service departments.

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Thank you for purchasing a Wittmann granulator.
Please record your granulator’s model and serial number and the date you received it in the table below.
Our service department uses this information to provide help for the specific granulator you installed.
Serial number / Date / Model
IMPORTANT
Wittmann is committed to a continued program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change
without notice.
All rights reserved. Any reproduction, editing, distribution, or other exploitation is prohibited.
This also includes excerpts.
Wittmann France SAS

Head office: 325 rue de Louis Barran - Centr’ Alp2 - F 38500 LA BUISSE - FRANCE
Tel.: +33 4 76 31 08 80 - Internet: www.wittmann-group.com

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Table of contents
HOW TO USE THIS MANUAL............................................................................................................................. 2
1 GENERAL INFORMATION............................................................................................................................. 6
1.1 INTRODUCTION .......................................................................................................................................................6
1.2 EXPLANATION OF SYMBOLS .......................................................................................................................................6
1.3 CHANGE ................................................................................................................................................................7
1.4 LIMITS OF LIABILITY ..................................................................................................................................................7
1.5 COPYRIGHT ............................................................................................................................................................7
1.6 CUSTOMER SERVICE CENTRE ......................................................................................................................................7
1.7 DEFINITIONS...........................................................................................................................................................7
2 SAFETY .......................................................................................................................................................... 8
2.1 INTENDED USAGE ....................................................................................................................................................8
2.2 CHANGES AND MODIFICATIONS ..................................................................................................................................8
2.3 EMERGENCY STOP...................................................................................................................................................8
2.4 DUTIES OF THE OPERATOR ........................................................................................................................................9
2.5 DUTIES OF THE PERSONNEL .......................................................................................................................................9
2.6 PERSONAL PROTECTIVE EQUIPMENT ............................................................................................................................9
2.7 ADHESIVE LABELS..................................................................................................................................................10
2.8 LABEL OVERVIEW ..................................................................................................................................................11
2.9 SAFETY SYSTEM .....................................................................................................................................................11
2.10 GENERAL SAFETY REGULATION ..............................................................................................................................12
3 SHIPPING INFORMATION ........................................................................................................................... 13
3.1 IN THE EVENT OF SHIPPING DAMAGE..........................................................................................................................13
3.2 IF THE SHIPMENT IS NOT COMPLETE...........................................................................................................................13
3.3 IF THE SHIPMENT IS NOT CORRECT .............................................................................................................................13
3.4 RETURNS .............................................................................................................................................................13
4 UNPACKING AND UNCARTING YOUR GRANULATOR ........................................................................... 14
4.1 GRANULATOR CONDITIONS AT THE RECEIPT ................................................................................................................14
4.2 UNCRATING THE GRANULATOR.................................................................................................................................15
4.3 HANDLING ...........................................................................................................................................................17
5 INSTALLATION ............................................................................................................................................ 17
5.1 PLACE OF USE .......................................................................................................................................................17
5.2 ELECTRICAL CONNECTION ........................................................................................................................................17
6 FUNCTIONAL AND TECHNICAL DESCRIPTION ....................................................................................... 18
6.1 FUNCTIONAL DESCRIPTION ......................................................................................................................................18
6.2 TECHNICAL INFORMATION .......................................................................................................................................19
6.3 SOUND DATA ........................................................................................................................................................20
6.4 OVERALL DIMENSIONS ............................................................................................................................................21
6.5 GENERAL VIEW .....................................................................................................................................................24
7 GENERAL SET-UP AND PRE-OPERATIONAL CHECKLIST ...................................................................... 31
7.1 DEGREASING ........................................................................................................................................................31
7.2 CHECK BEFORE THE FIRST START ...............................................................................................................................31
7.3 CHECKING AND OPERATING OUT OF VOLTAGE..............................................................................................................32
7.4 CHECKING AND OPERATING UNDER VOLTAGE ..............................................................................................................32
7.5 CONTROLS OF THE GRANULATOR ..............................................................................................................................33
7.6 SHUTDOWN CONDITIONS ........................................................................................................................................34
7.7 EXTERNAL CONTROL OF THE GRANULATOR ..................................................................................................................35
7.8 CONNECTION TO THE SUCTION PIPE...........................................................................................................................35
8 OPERATION ................................................................................................................................................... 36
8.1 CHECKS BEFORE STARTING.......................................................................................................................................36
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8.2 STARTING THE GRANULATOR....................................................................................................................................36
8.3 STOPPING THE GRANULATOR ...............................................................................................................................36
8.4 TWO HOURS AFTER THE FIRST START..........................................................................................................................36
8.5 FEEDING THE GRANULATOR .....................................................................................................................................36
8.6 OVERFILLING AND STOPPAGE OF THE GRANULATOR ......................................................................................................37
8.7 ACCESSING THE CUTTING CHAMBER ..........................................................................................................................38
8.8 CLOSING THE CUTTING CHAMBER..............................................................................................................................38
8.9 ACCESSING THE SCREEN ..........................................................................................................................................38
8.10 GRANULATOR LOCKING.........................................................................................................................................39
8.11 GRANULATOR SAFETIES.........................................................................................................................................39
8.12 CAPACITIVE SENSOR .............................................................................................................................................39
8.13 ADJUSTING THE SUCTION PIPE ................................................................................................................................39
8.14 END-OF-LIFE DISPOSAL .........................................................................................................................................39
9 MAINTENANCE ............................................................................................................................................ 40
9.1 LUBRICANT...........................................................................................................................................................41
9.2 PREVENTIVE MAINTENANCE SCHEDULE ......................................................................................................................41
9.3 TORQUE SPECIFICATIONS.........................................................................................................................................42
9.4 CHANGING THE DRIVE BELT......................................................................................................................................42
10 REPLACING AND ADJUSTING THE KNIVES .......................................................................................... 45
10.1 SAFETY INSTRUCTIONS AND CAUTION WHEN CHANGING KNIVES ....................................................................................45
10.2 ADJUSTING KNIVES FOR THE G-MAX 12 GRANULATOR................................................................................................46
10.3 PREADJUSTING THE KNIVES FOR THE G-MAX 23 AND G-MAX 33 GRANULATORS .............................................................46
10.4 SHARPENING THE KNIVES ......................................................................................................................................47
11 CLEANING .................................................................................................................................................. 48
12 WIRING DIAGRAMS................................................................................................................................... 52
13 TROUBLESHOOTING ................................................................................................................................ 52
13.1 ELECTRICAL PROBLEMS .........................................................................................................................................53
13.2 PROCESSING PROBLEMS ........................................................................................................................................54
13.3 TRANSMISSION ...................................................................................................................................................56
14 CUSTOMER SERVICE CENTRE ................................................................................................................. 57
15 SPARE AND WEAR PARTS ........................................................................................................................ 59
15.1 RECOMMENDED SPARE PARTS LIST ..........................................................................................................................60
15.2 TOP PRIORITY SPARE PARTS ...................................................................................................................................62
15.3 ADDITIONAL SPARE PARTS .....................................................................................................................................63
16. PARTS AND OPTION KITS ........................................................................................................................ 64
16.1 COMPLETE KIT OF CUTTING TOOL WEAR PARTS ..........................................................................................................64
16.2 OPTIONS KIT.......................................................................................................................................................65

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1 General information
1.1 Introduction
These operating instructions enable safe and efficient handling of the granulator.
The operating instructions are a component of the granulator and must be kept accessible to the personnel at
all times in the immediate vicinity of the granulator.
The user must have carefully read and understood these operating instructions before starting any work.
The present operating instructions were carefully prepared.
Nevertheless, no liability is assumed for possible errors or for direct or indirect damage occurring in connection
with any errors in these operating instructions.
1.2 Explanation of symbols

Warnings are subdivided into various classes.
They are preceded by signal words indicating the degree of danger.
The following symbols are used for warnings:
DANGER
Imminently hazardous situation resulting in fatal or serious injuries.
WARNING
Possible hazardous situation which can result in fatal or serious injuries.
ATTENTION
Possible hazardous situation which can result in minor injuries.
IMPORTANT
Possible situation which can damage the device.
NOTE
Points out useful hints, suggestions and information.
 Warnings indicated at the start of a section apply for the entire section and all of its subsections.
 Warnings referring to a subsection or the subsequent operating step are integrated in the relevant
procedure.
 Pay strict attention to all warnings and notes.

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1.3 Change
Wittmann reserves the right to make unannounced changes at any time.
Details in the illustrations in these operating instructions can differ from the actual circumstances.
1.4 Limits of liability

Wittmann assumes no liability for personal injury and/or material damage due to:
 Improper operation.
 Usage for purposes other than those intended.
 Changes to the device without the authorization of Wittmann.
 Non-compliance with the maintenance intervals.
 Usage of parts from other manufacturers without the authorization of Wittmann.
 Damage caused by inadequately qualified personnel.
 Non-compliance with the technical documentation.
 Usage of non-original spare and wear parts from Wittmann.
1.5 Copyright
All rights reserved.
Any reproduction, editing, distribution or other exploitation is prohibited.
This also includes excerpts.
1.6 Customer service centre

Our Customer Service is available to assist you.
See chapter 14 “Customer service centre” to find our subsidiaries addresses.
1.7 Definitions
These operating instructions use recurring terminology.
User
The user is the person who operates the device on his/her own responsibility or according to instructions.
Operator
The operator of a device is the person responsible for all of its processes (e.g. production supervisor, hall
manager, etc.). The operator instructs the users to perform a task.
Qualified personnel
Specialists, including persons whose training or education qualifies them to perform work professionally and to
recognise possible hazards.

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2 Safety
Wittmann granulators fully comply with very high safety requirements.
2.1 Intended usage

 The conventional G-MAX blade granulators are designed to granulate sprues close to the injection
moulding machine and under certain conditions also reject parts (please consult us before doing the
latter).
 The plastic waste must be free from contamination such as metal, poisonous, flammable or explosive
items or any other substances that in any way are unhealthy.
 The conventional G-MAX blade granulators are designed to consistently deliver clean homogeneous
granulate with a minimum of dust particles.
 The conventional G-MAX blade granulators are not intended for the processing of materials other than
plastics.
IMPORTANT
Any kind of improper usage of the granulator shall void the warranty claim.
Strictly follow all instructions referring to safety, operation, servicing and maintenance.
These operating instructions must be used by every person assigned to work on or with the
granulator.
DANGER
The plastic sprues / parts must be free from contamination and metal before grinding.
2.2 Changes and modifications

 Any types of changes to the granulator without the explicit consent of Wittmann are prohibited.
 Unauthorized changes void certificates, explanations, operating instructions, and training and service
documents.
2.3 Emergency stop

Pushing the emergency stop button causes an immediate shut-down of the granulator.
DANGER
Misuse can lead to serious injury or death.
Ensure that the cause of the Emergency Stop has been eliminated and all safety devices are
installed and functional before restarting the granulator.
Do not restart the granulator until the danger and its source have been eliminated.

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2.4 Duties of the operator
 Ensure proper usage of the granulator.
 Perform a general cleaning of the granulator before it is commissioned.
 Employ only instructed personnel or trained specialists and clearly define their responsibilities for
operation, maintenance and cleaning.
 Repair scratched or damaged adhesive labels before they become illegible. Labels must not be
removed.
 Routinely inspect the electrical equipment and replace any damaged parts immediately.
 Do not make any changes to the granulator which could impair safety without the approval of
Wittmann.
 Keep a fire extinguisher in the immediate vicinity.
 Arrange an emergency plan in case of fire or any other critical situation.
 Do not stand on or lean against the granulator.
2.5 Duties of the personnel

 Constantly check the granulator for functional capacity (product quality, missing parts, vibrations,
unusual noises, release of odours, etc.) and eliminate any noticeable problems immediately.
 Observe the safety information and warnings in the operating instructions.
 Never wear rings, wristwatches, neck ties, scarves, open jackets, loose clothing, etc. when working on
or with the granulator. This poses a risk of injury.
 Learn where the fire extinguishers are located and how to operate them and also the emergency plans
in the case of fire or any other crisis situation.
 Obtain information about the internal regulations regarding safety directives and always comply with
them.
2.6 Personal protective equipment

Wear personal protective equipment for all tasks.
This includes:
Safety shoes
 Non-slip
 Protection against falling parts
For particular tasks, additionally wear:
Gloves
 Protection against sharp-edged, hot or moving parts
Light breathing protection

 Protection against heavy dust formation
Hearing protection
 Protection against loud noises
Safety glasses
 Protective eyewear

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2.7 Adhesive labels
Repair scratched or damaged adhesive labels before they become illegible.
The labels must not be removed.
Beware of electrical voltage

Particular caution in the affected area
Don’t touch the drive belt, your hand could be dragged along
Beware of crushing
Check rotation direction
Do not introduce metallic parts
Do not insert body parts

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2.8 Label overview
NOTE
The item numbers of the adhesive labels are provided in chapter 15 "Spare and wear parts".
2.9 Safety system

 The granulator has a safety system to prevent access to dangerous components during operation.
 The granulator is equipped with a main switch, emergency stop, start button and safety switches to
avoid personal injury.
 The safety system must not be changed or modified under any circumstances.
 All maintenance and service to the safety system of the granulator must be carried out by personnel
with the necessary knowledge.
 Only spare parts from Wittmann may be used when replacing safety components.
 The main switch is located on the electrical cabinet and breaks all three poles of the incoming 3-phase
power.
 The emergency stop is activated by pressing the red button on top of the console. Safety switches will
break current in the granulator, so that the granulator stops if the cutting chamber, hopper, or screen
bracket are opened or if the bin is missing.
 The granulator cannot be started unless the cutting chamber is closed and the bin is in place.
 The granulator can be equipped with additional safety features depending on optional equipment.
IMPORTANT
The emergency stop on top of the console shall always be within reach of the operator.

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2.10 General safety regulation
 The granulator uses sharp knives for cutting up the material.
Consequently it can be a dangerous machine to operate and maintain unless certain safety
regulations are strictly observed.
 The regulations should be read, understood, and periodically reviewed by all personnel involved in any
way with the granulator.
 There is a risk of pinching or crushing the fingers associated with the pulley belt transmission of the
granulator. Always wear gloves when working on the transmission and follow the instructions of the
manual.
 The doors of the electrical cabinet and of the transmission must be kept closed when the granulator is
operating. Only authorized personnel are allowed to open these doors.
 Never operate or remove components bolted onto the granulator, unless the granulator is
disconnected from the power supply and its rotor does not move .
 Never operate the granulator without hopper and bin.
Do not bypass the safety interlocks.
 Prior to cleaning a jam or performing any maintenance, the rotor must be stopped and its motor
disconnected from the power supply.
Be sure that the rotor has come to a complete stop.
 Hands must not be inserted into the hopper to clear a jam.
 Do not extend any part of the body into the hopper as long as the motor is not disconnected from the
power supply and the rotor is motionless.
 Never extend fingers through holes in the screen.
 Extreme care should be taken to see that all bolts are properly tightened at all times.
During the operation of the granulator, bolts fixing the knives may come loose.
The tightness of these bolts has frequently to be checked.
 Take care when the knives are exposed, they are sharp and could cause personal injury.
 Wittmann granulators are designed for the granulation of plastic materials. Do not feed any
other materials into the granulator.
 The size and performance of the granulator is designed and chosen to suit the type of plastic waste
specified by the customer when ordering.
 Approval must be obtained from the Wittmann France head office for granulating other products and
materials.
 Wittmann’s granulators are designed so that maintenance and cleaning can be done quickly and
easily.
 Any modification or conversion of the granulator is subject to written approval from Wittmann France,
with the object of preventing injury or damage and to maintain the guarantee and the efficiency of the
granulator.
 For any questions, please contact the local Wittmann agent or Wittmann France .
DANGER

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3 Shipping information
 You should inspect your granulator for possible shipping damage.
 Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or
loose wiring and components, loose hardware and mounting screws etc.
3.1 In the event of shipping damage

 According to the contract terms and conditions of the carrier, the responsibility of the shipper ends at
the time and place of shipment.
 Notify the transportation company’s local agent if you discover damage.
 Hold the damaged goods and packing material for examining agent’s inspection.
Do not return any goods before the transportation company’s inspection and authorization.
 File a claim with the transportation company.
 If the shipment was prepaid, contact us for a receipted transportation bill.
 Advise customer service regarding your wish for assistance and to obtain a return material authorization
number.
3.2 If the shipment is not complete

 Check the packing list as back-ordered items are noted on the packing list.
You should have:
- Granulator
- Operation and installation manual on CD
- Wiring diagrams
- Delivery note (European destination)
- List of weights and packing list (outside Europe)
- Invoice (outside Europe)
 Re-inspect the container and packing material to see if you missed any smaller items when unpacking.
3.3 If the shipment is not correct

 If the shipment is not what you ordered, contact the shipping department. Have the order number and
item number available. Hold the items until you receive shipping instructions.
3.4 Returns
 Do not return damaged or incorrect items until you receive shipping instructions from our Sales
department.

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4 Unpacking and uncarting your granulator
WARNING
Possible injury due to heavy device/component.
Always use suitable equipment (forklift, hoisting crane, etc.) for moving the granulator and
accessories.
Only appropriately qualified personnel may operate transport and lifting equipment.
Always use the sling points provided/labelled for moving the devices and accessories.
 Ensure that no metal parts or packing materials are located in the granulator.
 Perform a general clean.
4.1 Granulator conditions at the receipt

 The granulator and accessories are delivered packed on a pallet or inside a crate.
 At the delivery: check that the granulator has no damage due to the freight: scratches, bumps, foreign
components, rusty and dampness.
 Remove all packaging and protective films.
 Verify the completeness of the delivery in accordance with the delivery note.
CAUTION
In case of damages, immediately notify the carrier.
Wittmann will not be responsible for the damages, if carrier is not immediately notified.
Be certain that the area to be occupied by the granulator is clean, level, and free of obstructions.
Make sure the floor is rated to adequately support the weight of the granulator.
The granulator should be set on a concrete floor.
Place the granulator so you can access electrical components, transmission, screen, cutting
chamber and hopper. Maintenance personnel should have unobstructed access to the granulator.
There should be adequate clearance maintained between machines, walls etc.
The hinged hopper and the doors of the electrical cabinet and transmission should have full swing.
IMPORTANT
Inspect the granulator for visible transport damage.
Please note that various devices can be disassembled for transport.
Do not use any sharp or pointed objects - they can damage the surfaces and the granulator itself.

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4.2 Uncrating the granulator
 Take off the packing protections.
 Take off the bin and unscrew the fastening of the pallet.
 Use the designated lifting points.
 Use a hoist and hook.
 Hook as follows on the drawing, and lift up the granulator to remove the pallet and place down the
machine at the same place.
 Move the granulator skilfully and slowly.

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4.3 Handling
 The granulator is fitted with casters (2 swivelling with brake and 2 fixed).
 Do not move the granulator on uneven ground. In such a case, use a handling machine with brake
and securely tie the granulator with a rope.
 Block the two brakes when the granulator is in its permanent position.
5 Installation
 May only be performed by qualified specialists.
 Wear protective clothing (protective work clothing, safety shoes, gloves).
 During all installation work the machine must be disconnected from any energy source.
5.1 Place of use

 A free space is needed around the granulator to facilitate cleaning, service and maintenance.
 Check and make sure that the granulator is placed on a flat ground that is sufficiently strong while the
granulator is in operation.
 For being able to open the hopper, the doors of the electrical cabinet and the transmission
compartment, sufficient space must be kept clear around the granulator allowing the passage of the
user. Check the layout of the granulator to see how much space your granulator requires.
 Ensure that the granulator stands horizontally and steady.
IMPORTANT
Take care to ensure that no small parts (screws, nuts, etc.) can fall into the material feeding devices.
5.2 Electrical connection

 The rated connecting voltage and the size of fuses for the granulator are stated in the electrical circuit
diagrams.
 Inspect the function of the protective ground.
 Check all of the electrical connections and screw connections for tightness.
 Emergency stop shall always be within reach of the operator.
 Connect the granulator to the main power supply.
DANGER
High voltage. Danger to life.

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6 Functional and technical description
6.1 Functional description

 The conventional G-MAX blade granulators are equipped with blades and a screen for cutting up and
processing sprues and other plastics wastes.
 The granulator must be used according to its power and throughput.
 The material is introduced inside the hopper manually, by robot, or conveyor belt.
 Sprues and parts are cut inside the cutting chamber by the blades and sorted out by the screen
openings.
 Due to gravity the regrind falls into the bin.
 The bin is emptied manually, mechanically or by an aspiration system.
WARNING
The conventional G-MAX blade granulators are not made to granulate: heavy or hard pieces, flush,
metal part, glass, paper, wood, toxic or flammable parts or to work inside an explosive area.
 The conventional G-MAX blade granulators are rugged, rotary-cutting machines specifically designed
to cut, chip and granulate plastic materials.
 The G-Max 12 granulator has a staggered rotor with 12 knives specially designed for the grinding of
middle hard materials and thick sprues.
 The G-Max 23 and 33 granulators have a hybrid rotor design with 2 x 3 progressively cutting open
blades and 3 x 3 mobile blades producing a clean scissor type cut and allowing better cooling of the
regrind by letting pass air under the blades.
 Sound level may vary and is dependent on the type of granulated plastics, the shape of granulated
items, granulator feed equipment and the general surroundings (premises).
 The sprues/parts are fed into the hopper and fall down into the cutting chamber, where rotating knives
cut the plastics against fixed knives to granulate.
 A perforated screen determines the size of the granulate.
 The screen is located under the cutting chamber and can easily be changed to give the desired
granulate size.
 The particles passing the screen fall into the regrind collection bin where a suction pipe allows the
connection to an optional extraction device.
 The extraction device (option) ejects the granulate which is then ready for reuse in the production
machine or for transportation to a container for later use.
 The device is rapidly cleaned as all the places of the cutting chamber that need cleaning are easily
accessible. Colour and type of the plastic material can therefore be changed without loss of time.
DANGER

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6.2 Technical information
Conventional blade granulators G-Max 12 G-Max 23 G-Max 33
Motor output 1,5 kW 3 kW 4 kW
Rotor speed 200 rps - 50 Hz / 240 rps - 60 Hz
Fixed knives / blades 2 2 4
Rotating knives / blades 4x3 2x3 3x3
Double scissors cutting action ● ● ●
Diameter of cutting circle 180 mm 220 mm 220 mm
Hopper opening 252 x 155 mm 310 x 190 mm 453 x 190 mm
Interior passage of the hopper 259 x 150 mm 310 x 205 mm 460 x 190 mm
Cutting chamber 169 x 198 mm 310 x 235 mm 460 x 235 mm
Diameter of screen holes Standard 5 mm (conical holes)

Optional: 4 - 6 – 8 mm straight, slanted, conical holes
Fly wheel ● ● ●
Regrind bin volume 10 l 13 l 16 l
Throughput* 50 kg/h* 80 kg/h* 110 kg/h*
High level capacitive sensor for regrind ● ● ●
Electrical cabinet with “main disconnect switch”,

Electrical components and safety Console with “emergency stop button”, “On/Off button”
Safety switches for the cutting chamber and the bin
Electrical cord with CEE plug 3 Phases 16A + neutral + ground / length 6 m
Machinery directive 2006/42/EC

EMC Directive 2004/108/EC
EC declaration of conformity EN ISO 12100:2010
EN 60204-1 (2009:12)
NF EN 12012-1
Wear parts Blades, screens, drive belt
Weight 220 kg 300 kg 340 kg
Drawings GM12910 GM23910 GM36910
* Depending on material and geometry of runners, sprues and/or parts, regrind size etc.

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6.3 Sound data
Granulator used for sound measurements G-Max 33
Serial number 16010

Power supply 400 V / 3 Ph. 50 Hz
Rotor speed 200 rps @ 50 Hz
Number of moving blades 3x3
Diameter of screen holes (mm ) 5 mm
Feeding Manual
Temperature of material Ambient
Temperature of testing room +20°C
Based on the following standards: EN ISO 11202 1995(F) – EN ISO
4871 1996
Mounting and functioning conditions of the measurements:
o Measurement in closed area of dimensions : 10 m x 5.5 m x Height 2.5 m without soundproofing.
o An ACLAN SGD 80F n°90220 sound analyser was used for the noise measurements.
o Manual feeding of sprues by an operator.
o Measurement is done after closing the curtains of the feeding entrance.
o All other apertures are closed.
Unstable noise due to chosen low value.
o Amount of samples and materials
o Samples A: ABS sprues
Dimensions: 80 x 80 x 50 mm - Weight: 6 g - Cycle time: 10 s - Feeding by 5
o Samples B: PA 6-30%FG sprues
Dimensions: 60 x 60 x 60 mm - Weight: 16 g - Cycle time: 10 s - Feeding by 5
o Samples C: PE/PP sprues
Dimensions: 40 x 30 x 20 mm - Weight: 5 g- Cycle time: 10 s - Feeding by 10
o Samples D: Polyurethane Sprues
Dimensions: 120 x 60 x 60mm - Weight: 6 g - Cycle time: 10 s - Feeding by 5
Measured equivalent sound pressure levels: Sample A=69
LAeq=Db(A) of measurement: 2 Db Sample B=75
Sample C=67
Sample D=64
Measured peak acoustic pressure level: Sample A=74
Sample B=78
LCpeak=Db(C) of measurement: 2 Db
Sample C=74
Sample D=67

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6.4 Overall dimensions
6.4.1 Granulator G-Max 12

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6.5 General view
1 Feeding funnel 12 Handle

2 Hopper 13 Anti-fly-back curtain
3 Opening system for hopper and screen 14 Cutting chamber
4 Screen bracket 15 Safety switch on cutting chamber
5 Regrind bin 16 Name plate
6 Swivelling casters with brake 17 Locking device for automatic belt tensioner
7 Fixed casters 18 Motor
8 High level capacitive sensor for regrind 19 Frame
9 Pulley belt transmission compartment 20 Safety switch ensuring the presence of the
screen
10 Electrical cabinet 21 Indicator of the direction of rotation of the
granulator
11 Detachable console
6.5.1 Hopper
 The hopper is designed to remain stationary.

 The hopper is an upright soundproofed enclosure bolted onto the upper part of the cutting chamber.
 The hopper is designed to facilitate the feeding of the material to the cutting tools and to prevent
particles ejected from the cutting chamber from hitting the operator (anti-fly-back curtain).
6.5.2 Drive system
 The rotor is driven by the motor through a pulley and belt arrangement. The compact massive pulley on
the rotor creates a high inertia rotor system allowing very efficient granulating. An automatic belt
tensioning system makes sure that the belt stays always correctly tensioned.

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6.5.3 Cutting chamber
 The cutting chamber is a rectangular enclosure comprising the main frame, the fixed knives, a
balanced rotor and the sorting screen.
 The screen is supported in position below the rotor and acts as a separating barrier to the granulated
material, retaining the material in the cutting chamber until the particle size is such that it will pass
through the screen holes.
 The screen can be pulled out for cleaning. Screens with holes of different types and sizes are
available as options.
 A latch finger keeps the screen bracket in place when the hopper is opened.
 The rotor carries the rotor knives. The rotation of the rotor produces a cutting action between the rotor
knives and the stationary knives, thus reducing the material size.
 The cutting chamber is mounted over 4 vibration absorbing elastomer blocks on the frame.
1 Screen bracket 7 Adjusting the fixed blades

2 Bearing housing 8 Vibration absorbing block
3 Rotor 9 Latch finger of screen bracket
4 Fixed blade 10 Screen
5 Rotating blade 11 Collection bin stop
6 Anti-wrap blade

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6.5.4 Regrind bin and suction pipe
 The granulated material that falls through the screen is collected by the collection bin located beneath
the cutting chamber.
 A stop keeps the collection bin in position.
 The regrind bin has an exit tube allowing the connection of a discharge pipe in different directions.
 The suction pipe for the connection of a discharge pipe with a diameter of 40 mm or 1’’1/2 has 3 holes
for adjusting the air flow. It is kept in position by a spring blade.
 An adapter ring for connecting a hose of diameter 50 mm or 2 inches is supplied with the suction pipe.
 The pipe and the aspiration system of the granulator are not included in the equipment supplied.
1 Spring blade holding the pipe in position 3 Centring ring for blanking off
2 Adapter ring for diameter 50 mm or 2’’ 4 Regrind suction pipe with 3 holes for
For diameter 40 mm or 1’’1/2 take off the ring. adjusting the air flow

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6.5.5 Safety switches
 The main disconnect switch connects the granulator to the power supply or disconnects it from it.
 The G-Max granulators feature safety switches making sure the cutting chamber is closed and the
screen is present.
 Check all safety switches periodically for proper operation.
 The granulator can not operate safely if the safety switches are removed.
 One safety switch (1) ensures the hopper is locked and prevents the granulator from starting if this is
not the case.
 A second safety switch (2) ensures the presence of the screen and prevents the granulator from starting
if there is no screen.
 For opening the cutting chamber a knob has to be unscrewed. The time it takes to unscrew the knob
makes sure that the rotor has completely stopped.
 The hopper is build with a safety distance preventing the operator from accessing the cutting tools.
 A circuit-breaker protects the motor against overloads.
1 “Cutting chamber” safety switch

2 “Screen present” safety switch

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6.5.6 Safety stickers
Stickers on the doors of the electrical cabinet and the transmission warn against potential danger.
6.5.7 Nameplate
Certificate of conformity Serial number *
Year of manufacturing
Name/Model
Power supply
Weight
Current
Connected load
*The serial number is also marked on the topside of the cutting chamber.
NOTE
Please specify the serial number of the granulator in the case of questions, complaints, spare
part orders, etc.
6.5.8 Standard features
 Pulley belt transmission with automatic belt tensioner.

 Three-phase voltage operation. Refer to the unit nameplate for proper voltage and amperage
requirement.
 Capacitive high level sensor for regrind bin level (sensor is located underneath the cutting chamber)
with sound and visual alarm.
 Soundproofed stainless steel hopper.
 Electrical cabinet with disconnect switch, safety protection, start system, circuit breaker and control
board.
 Control plate with with start/stop button, emergency stop button, status light.
 Safety devices for closed cutting chamber and bin detection.
 Stainless steel regrind collection bin with an adjustable exit tube allowing the connection of a suction
pipe with adjustable air flow.
 Four casters (2 fixed and 2 swivel type with brake).

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6.5.9 Options according to the valid pricelist
6.5.9.1 Knife gap pre-adjustment device to pre-set the knife gap (for granulators G-Max 23 and G-Max 33)
With this device the knives can easily be pre-set outside of the cutting chamber.
6.5.9.2 Cooling circuit

This device allows to cool the cutting chamber by water flowing from an external water supply (not provided)
through the cutting side of the fixed blades. 2 sealing couplings are supplied for the connection of hoses with an
inside diameter of 10 mm.
6.5.9.3 Magnet
The magnet holds back certain ferromagnetic particles falling into the hopper and prevents them from being cut.
6.5.9.4 Screen
The standard screen supplied with the granulator has conical holes with a diameter of 5 mm for letting pass the
ground material rapidly.
Other screens with straight or inclined holes of diameters 4, 5, 6 or 8 mm are available.
Inclined holes should be used for very fine sprues with smaller diameters than the holes of the screen.
6.5.9.5 Automatic bin emptying (OPTION J)

The high level detection sends a signal to a Wittmann Feedmax hopper for emptying the bin. This option is
supplied with a 3 poles / ground connector and a cable of 6 meters. The granulator stops, if the level of the bin
does not go down after an adjustable time delay.
6.5.9.6 External On-Off (OPTION D)

The granulator can be started and stopped by external signals from an injection moulding machine, a robot or
another device, allowing substantial energy savings.
Stopping the granulator is delayed by 60 seconds to finalize the grinding phase. This timer can be set directly
on the control panel.
This option is supplied with a connector and a cable of 6 meters. It also allows the granulator to send back a
signal indicating its state (operating or fault).
6.5.9.7 Antistatic capacitive sensor

Certain electrostatically charged plastic materials can disturb the standard capacitive sensor. An antistatic
sensor does not attract the charged particles and allows the operation of the granulator under difficult conditions.
6.5.9.9 Wear parts kit

See chapter 16 "Parts and option kits".
6.5.10 Special demand options
 Special Hopper.
 Particular supply voltage.
6.5.11 Requirements for the installation site
Temperature range +5 – 40°C

Relative humidity (%) 65
Maximum altitude 1000 m
 Install the granulator solidly in a closed, dry and ventilated area.

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 Prevent abrupt temperature and humidity changes.
 Consider the stability of the installation site, particularly when installing the granulator on platforms.
 Floors must be level, non-slip, dry and easy-to-clean.
 Please ensure that all parts of the granulator remain accessible for servicing and repair work.

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7 General set-up and pre-operational checklist
7.1 Degreasing
 Degrease the granulator to take off the rust protection.
 Clean inside the hopper, cutting chamber, and bin.
 You may use a soft cleaner, or degreaser.
Apply with a brush or an atomizer and immediately dry it.
Be careful not to touch the seals, the plastic components and the painted parts.
 Carefully inspect the interior of the cutting chamber and the regrind collection bin for foreign material
or debris.
IMPORTANT
 Grind raw materials which will not be re-used for degreasing the granulator during its first
run.
7.2 Check before the first start

 Make a thorough general inspection.
 Check that there are no loose parts, screws, nuts or components in the granulator.
 Check the tightening torques of fixed and rotating knives.
 Check the knife clearance using a feeler gauge, check in the middle of the rotor and at the outer ends,
the knife clearance must be between 0.15 and 0.4 mm.
 Flaps in the hopper: Check that the flaps are undamaged. Replace damaged flaps at once. Damaged
flaps increase the risk of material ejection when operating.
 Check inside the electrical cabinet the magnetic trip level adjustment of the circuit breaker (component
marked QF inside the cabinet). The value to be set is shown on the circuit diagram and it depends on
the mains supply of the granulator.
 Emergency stop: Check the emergency stop function.
 Cables: Check the electric cables of the granulator for wear or other damages. Replace damaged
cables at once.
 Check the function of the safety switches.
 Check the tightening torque of the screws holding the motor on the frame.
NOTE
Report the executed inspection in the granulator maintenance schedule.

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7.3 Checking and operating out of voltage
 Refer to the nameplate of the granulator for proper voltage and amperage requirement.
 Make sure to provide a correctly-sized and protected supply of electrical power to the granulator.
 Check serial tag voltage/amperage requirements and make sure your electrical service conforms
before making any electrical connections.
 Bring properly sized power leads and grounds from a circuit-breaker or a fused disconnect switch to
the granulator. Provide external overcurrent protection to the granulator, using circuit breakers or
fuses.
If you use fuses, make sure that they are time-delay fuses, sized according to your mains supply.
Make sure all electrical connections are tight.
 Electrical connections must comply with applicable electrical codes.
Voltage must be within plus or minus five percent of the nameplate rating.
Make sure the cables used are not damaged.
 Check that there is no part inside the cutting chamber.
 Check that hopper is locked and the screen is in place.
 For a granulator delivered out of EC, without plug or cable, fit up the right cables and plugs.
7.4 Checking and operating under voltage

 Connect the plug to the mains supply of the location.
 Turn the main disconnect switch to position ‘1’
 The indicator light “Under voltage” will turn “Green”
 Check that the emergency stop button is unlocked
 Push the “Green” button to start, a LED light will turn “On” to show that the rotor is rotating
 Push the “Red” button to stop the rotor, the LED light will turn “Off”
ATTENTION
Check the direction of rotation of the granulator motor in relation to the arrow on the end of the shaft.
If the rotor rotation is incorrect, turn off the granulator, turn the main disconnect to “Off”, unplug the
granulator and reverse phases.
 Check all other accessories are correctly turned on (evacuating system, high level sensor…).
 Check the safety systems of the cutting chamber and the bin detection.
 Make sure there is no unusual noise from the pulley belt transmission.
 In case of any problem do not use the granulator until Wittmann service has been contacted.
ATTENTION
If the safety systems are modified, Wittmann will not be responsible for any damage and/or accident.

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7.5 Controls of the granulator
On/Off button
Indicator light « Under voltage » Indicator light when the rotor is

turning
Main disconnect switch Emergency stop button
NOTE
The keys of the doors of the electrical cabinet and of the transmission are safety components.
These keys must be kept by the persons who are responsible for the safety, the operation and
the maintenance of the granulator.

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Turning the granulator “On”
 Make sure the cutting chamber is locked and the screen is in place.
 Unlock the emergency stop button
 Turn the main disconnect switch to position ‘1’.
 When the granulator is under voltage, the white indicator light turn « On »
 Push the green button.
Turning “Off” the granulator
 Push the red button.

Opening the cutting chamber

 Unscrew the locking knob (1 + 2).
 Open the locking knob (5)
 Hold the hopper carefully while opening (4).
 No tools are needed to open the cutting chamber.
7.6 Shutdown conditions

 To shut the granulator down, allow all material to pass through the cutting chamber before pressing
the stop button.
 Parts must be cleaned out of the hopper and cutting chamber prior to restarting.

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7.7 External control of the granulator
 The granulator can be started and stopped by an injection moulding machine, a robot, or another
external device. Such a control allows substantial energy savings, as the granulator can be switched off
when the devices feeding the granulator don’t work.
 The start/stop plate remains active and the operator can still start and stop the granulator, even if it is
controlled from an external device.
 When an external device asks to stop the granulator, an adjustable delay ensures that all parts are cut
up before the granulator actually comes to a stop.
 2 relay terminals are available (On / Off) for connecting directly a control cable from an external device.
These terminals are marked as X1-11, X2-11, X3-11 on the circuit diagram of the granulator. 24V AC/DC
signals have to be transmitted. The cable can easily be inserted through a free cable gland.
 An option kit with the cable and male and female connectors is available (see chapter 16 "Parts and
option kits").
7.8 Connection to the suction pipe

 The suction pipe is intended for connecting a spiral hose.
- For connecting a hose of diameter 40 mm or 1’’1/2, take off the adapter ring and push the
hose directly over the pipe.
- For connecting a hose of diameter 50 mm or 2’’, push the hose over the adapter ring and
fasten the ring with its screw.

Translation Page 35
8 Operation
8.1 Checks before starting

 Block the brakes of the two swivelling castors.
 Place the screen and check that it is correctly positioned.
 Ensure that all surfaces that make contact with one another are well cleaned before closing.
 Close the screen bracket and the hopper by screwing the knob all the way down.
 Observe caution because there is danger of crushing your fingers when closing.
8.2 Starting the granulator

 Make sure the regrind bin is installed properly.
 Make sure the screen bracket and the hopper are correctly closed.
 Unlock the emergency stop button on the console.
 Turn the main disconnect switch to the position ‘1’.
 When the granulator is under voltage, the white indicator light turn « On »
 Push the green button to start the granulator
8.3 Stopping the granulator

 Do not introduce any more sprues / parts into the granulator.
 Wait till all the material inside the granulator is completely cut up and the regrind bin has been emptied
by the aspiration system (if installed).
 Push the red button to stop the granulator
 Remove the electrical plug from the main power supply of the granulator.
 If the granulator is stopped with material left in the hopper, the material remaining in the cutting chamber,
regrind bin or transport system could clog the cutting chamber and the material conveying system during
re-start.
 The granulator motor could be overloaded and trigger an overload protection.
8.4 Two hours after the first start

 Check the tightening torque of all screws fastening the granulator knives.
 Check the knife clearance / gap.
 Check the tightening torque of the screws holding the motor on the frame.
 Check the position of the belt on the drive pulleys and driven pulleys.
 Make a thorough general inspection of the granulator.
 Ensure that there are no objects like screws, nuts or components left inside the granulator.
 Report the executed inspection in the granulator maintenance schedule.
8.5 Feeding the granulator

 Feed the granulator through the hopper
 For maximum efficiency, the granulator should be fed at a rate that is consistent with its capacity, that
is indicated in the table of section 6.2. If, for example, the G-MAX granulator is rated at 60 kg/h then
the optimal feed should not exceed 1 kg/min.

Translation Page 36
DANGER
Under no circumstances should the operator attempt to reach into the hopper to dislodge any
bridged or jammed material while the granulator is in operation.
To clear the hopper of jammed material, the granulator main power must be turned off and the
granulator disconnected from the mains power.
8.6 Overfilling and stoppage of the granulator

 If the granulator is overloaded, the cutting chamber works at its limits and could get jammed.
 Turn the main disconnect switch of the granulator to “0” and remove its plug from the mains power
connection.
 Open the hopper carefully for getting access to the cutting chamber (see section 8.7).
 If the cutting chamber has jammed, use a piece of wood and carefully try to release the rotor in
reverse rotation direction.
 Clean the hopper, cutting chamber, screen, and regrind collection bin of the cut up material.
 Reset the granulator motor’s overload protector in the electrical cabinet.
 Look for the cause of overfilling the granulator.
 Check the knives and the gap between the fixed and moving knives. If the granulator knives are blunt
and un-sharpened or if the knife clearance is incorrect, this can cause overfilling in the cutting
chamber.
 To sharpen or replace the knives, or adjust the knife clearance see chapter 10 “Replacing and
adjusting the knives”.
 Check the screen. The dimension of the holes in the screen must be appropriate to the material to be
granulated and if the size of the holes is wrong, this can lead to overfilling in the cutting chamber.
 Look for the cause of the stoppage in the hopper:
- The hopper feed speed is too high or sprues/parts are too large.
- Clean the hopper and lower the feed speed.
- The cutting chamber is overfilled: Look for the cause of the overfilling in the cutting
chamber. See previous section.
NOTE
Before trouble shooting, attending to mechanical faults and maintenance work, turn the main
disconnect switch of the granulator to “0” and remove its plug from the mains power
connection.

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8.7 Accessing the cutting chamber
 You will need to access the cutting chamber before initial start-up and for various maintenance and
cleaning procedures.
Use the following procedure to access the cutting chamber:

- If the granulator is working, stop the granulator by pressing the stop button on the console.
- Turn the main disconnect switch to ‘0’ and remove the granulator’s plug from the mains
socket.
- Unscrew the locking system of the cutting chamber to open its safety switch.
- Slowly swing the hopper to the opening position, do not allow it to drop freely of its own
weight.
- Shift the stop to take out the regrind bin.
- Carefully open the screen bracket by pulling on its latch finger.
- You have now complete access for work in the cutting chamber.
8.8 Closing the cutting chamber

 Throughly clean the closing surfaces on the screen bracket, on top and the bottom of the cutting
chamber and the bottom of the hopper.
 Close the screen bracket with the screen in place
 Carefully swing the hopper back into the closed position.
 Screw on the locking system of the cutting chamber to close its safety switch.
 Reconnect the granulator to the mains power supply.
8.9 Accessing the screen

 Shift the stop to take out the regrind bin (1 + 2).
 Unscrew the knob locking the cutting chamber.
 Pull the latch finger (3) closing the screen bracket.
 This frees the screen bracket that can now be opened.
 The screen (4) is accessible and can be removed, cleaned or changed.

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8.10 Granulator locking
 Before installing a screen, clean the contact surfaces of the screen and the screen bracket. Jammed-in
particles could prevent the granulator from locking properly in which case the safety switches would
keep the granulator from starting.
 Put the screen into its bracket and make sure it is correctly positioned.
 Pull up the screen bracket until it gets locked by its latch finger.
 Close the hopper.
 Screw on the knob to close the safety switch.
 Shift the stop to fix the regrind bin in position.
8.11 Granulator safeties

 Safety switches are installed on the granulator to make sure the cutting chamber is properly locked and
the screen is correctly positioned.
 If the safety switches are not engaged the granulator does not work.
8.12 Capacitive sensor

 The capacitive sensor stops the granulator if the regrind bin is filled. An audible and visual alarm is
given.
 The regrind bin must be emptied by the operator or by switching on an external aspiration system.
 The sensitivity of the capacitive sensor can be set by turning the screw on its top (adjusting by up to 20
revolutions of the screw).
8.13 Adjusting the suction pipe

 The regrind aspiration force can be set by closing or opening the 3 holes on top of the tube. This can be
done:
- for a tube of diameter 40 mm or 1’’1/2 by pushing the hose more or less far onto the pipe.
- for a tube of diameter 50 mm or 2’’ by moving the adapter ring on the pipe (after loosening
the set screw of the ring).
8.14 End-of-life disposal

 The granulator contains:
- metals,
- plastic materials,
- electrical components.
NOTE
All waste material should be disposed of in accordance with local regulations.
Comply with all local regulations concerning waste separation and disposal. It is advisable to charge
a specialized company with this task.

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9 Maintenance
WARNING
All operations of maintenance and cleaning have to be done out of voltage with the mains plug
disconnected.
All service must be carried out by trained personnel in order to avoid personnel injury or damage to
the granulator.
IMPORTANT
Safety clothes are necessary to avoid any risks of accidents.
For each spare parts order, please contact the local Wittmann after sales service.
Do not forget to mention the type of granulator, serial number, item code of the parts required and
quantity needed.
All parts which are not from Wittmann are forbidden.
Warranty: Refer to our general sales terms.
NOTE
When the cutting chamber is opened for cleaning or maintenance work, we recommend to put a
protection plate over the cutting chamber to avoid getting injured by the knives.

Translation Page 40
9.1 Lubricant
9.1.1 Bearings
 Bearings are sealed and lubricated for life.
9.1.2 Drive belt
 If the belt produces any frictional noises on the tensioner pulley spray some silicone on the belt. (refer
to chapter “transmission 13.3” )
9.2 Preventive maintenance schedule
Equipment / Part Service Wearing points Intervals
Blunt cutting edges

Sharpening or replacement
Clearance between fixed According to
Blades / knife Tightness of the screws
and rotating knifes 0.15 - usage
fastening the knives
0.25 mm
Screen Cleaning or replacement Obstructed by regrind According to
Surface worn out usage
Enlarged diameter of its
holes
According to
Anti-wrapping blade Check and change if necessary Blunt cutting edges
usage
Screws for tightness Blades / knifes, hopper Monthly
Checking of the thread
Clean and check the thread of
on anti-dust rings on the Dirty or obstructed Monthly
the anti-dust rings
inside of the bearings
Check the belt and the
tensioner pulley
Belt and automatic Friction, cracks, looseness According to
tensioning system Check the position of the belt usage
Centred on the pulleys
on drive and driven pulley and
tensioner pulley
Looseness, cracks,
Vibration absorbing pads Check for wear Once a year
deformations
Check fastening and change if
Safety switch Malfunction Once a year
necessary
According to
Capacitive sensor Cleaning Malfunction
usage

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9.3 Torque specifications
Thread 8.8 10.9 12.9
M5 5,5 N.m 8,1 N.m 9,5 N.m
M6 9,5 N.m 14 N.m 16,4 N.m
M8 23 N.m 34 N.m 40 N.m
M10 46 N.m 67 N.m 79 N.m
M12 79 N.m 116 N.m 120 N.m
M14 127 N.m 187 N.m 200 N.m
9.4 Changing the drive belt

A worn or broken belt has to be replaced. Proceed as follow:
DANGER
Stop the granulator, by pressing the emergency stop button. Put the main disconnect switch to
position “0”. Remove the mains plug of the granulator from the electric power supply.
To prevent injuries or damage to the granulator such work may only be performed by qualified
personnel.
When turning the pulleys by hand take care not to pinch or crush your fingers between the belt and
any of the pulleys.
The belt is tensioned by the automatic tensioning system. To avoid injuries reduce the tension
gradually and keep some distance to the tensioner pulley.
Open the cover of the transmission Unscrew and remove the positioning screw
compartment screw of the tensioning device

Translation Page 42
Gradually unscrew the 2 screws to slowly loosen
Remove the used belt.
the tensioner that begins to turn.
Place the new drive belt correctly on the pulleys as indicated below
G-Max 23 G-Max 33
G-Max 12
Insert and tighten the positioning screw of the

Use a tool to put tension on the tensioner
tensioner
Check manually that the pulleys turn smoothly

Tighten the 2 screws keeping the tension
and that the drive belt is correctly positioned

Translation Page 43
Close the cover of the transmission
compartment
Let the granulator run during 30 minutes, than open the cover of the transmission compartment and make sure
the belt is properly positioned on the pulleys. Put the cover of the transmission compartment back on again.
If there is any noise at the tensioner pulley spray some silicone onto the smooth outer surface of the drive belt.

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10 Replacing and adjusting the knives
IMPORTANT
The rotating and fixed blades work under severe conditions and the sharpness of the cutting edges
should regularly be checked.
The sharper the knives are kept, the better the granulator operates, producing quality regrind.
During use, the clearance between the rotating knives and the fixed knives will increase due to wear.
This is a normal condition that requires re-setting this clearance once or twice before it is necessary
to remove the knives for sharpening.
When new knives are fitted to the rotor, adjustment after eight hours of running time may be
required.
Before assembling a new sharp set of knives, make sure the knife seats and mounting holes are
clean.
Do not use grease or oil on screws or tapped holes when assembling the knives.
Knives must be replaced in complete sets otherwise it will not be possible to obtain even clearance
between the rotating and fixed knives.
We recommend that the rotor knife screws be replaced with new screws every knife change to
reduce the risk of screw failure due to overstretching.
Screws must be replaced with the type specified in the list in section 10.5.
Rotor knives should be changed one set at a time to prevent rotor from being out-of-balance.
ATTENTION
Before applying a wrench to any knife bolt, be certain that the rotor is blocked to prevent rotation.
One method to do this is to introduce a block of wood between a knife and a fixed portion of the
frame.
WARNING
Stop the granulator, by pressing the emergency stop button. Put the main disconnect switch to
position “0”. Remove the mains plug of the granulator from the electric power supply. Use a padlock
to prevent the main disconnect switch from being switched on.
To prevent injuries or damage to the granulator such work may only be performed by qualified
personnel.
10.1 Safety instructions and caution when changing knives

 Always use protective gloves when changing the knives.
 When screws on knives are removed or installed, always secure the rotor using a strong block of
wood to prevent it from moving.
 Each time a set of knives is changed, the screws which hold the knives must be replaced with original
Wittmann screws.
 Wittmann’s responsibility and guarantee becomes invalid unless genuine Wittmann screws and knives
supplied by Wittmann are used.
 All screws must be tightened using a torque wrench to specified tightening torque from table of section
10.5 of this manual.
 If a torque wrench is not used or if screws are not tightened to the specified tightening torque of the
present manual, Wittmann’s responsibility and guarantee become invalid.
 Check the screen for wear when changing the knives.
 Change the screen when holes are visibly worn out.

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 The G-MAX 23 and 33 granulators are manufactured with sufficient precision that all knives in the
granulator can be pre-set on a pre-adjustment device before they are installed in the cutting chamber.
The clearance between the fixed and rotating knives must be between 0.15 and 0.40 mm.
 The pre-adjustment device is available as an option.
WARNING
 Be very careful when turning the rotor by hand to avoid injury.
10.2 Adjusting knives for the G-Max 12 granulator

 The position of the fixed knives can be adjusted.
 The rotating knives can not be adjusted and must be replaced if they are worn out.
Mounting of fixed blade Mounting of rotating blade
NOTE
All knife positions must be properly cleaned and free from oil, grease and dust.
Use a plastic or rubber mallet and knock/hammer the knives down and in against the rear of the
knife position.
ATTENTION
Before connecting the granulator, turn the rotor by hand to check the gap between moving and fixed
blades (to be sure they don’t hit each other).
Recommended gap 0.15 to 0.40 mm
10.3 Preadjusting the knives for the G-Max 23 and G-Max 33 granulators
 The fixed and rotating knives must be preadjusted before mounting them on the G-Max 23 and G-Max
33.
 The optional pre-adjustment device allows to install rapidly and precisely the fixed and rotating knives
on the G-Max 23 and G-Max 33 granulators.
 Mount the adjustment screws behind the blades.
 Place the blade inside the pre-adjustment device and screw in manually the adjustment screws behind
the blade.
 Use a hex wrench (8 mm) and unscrew the adjustment screws until they touch the stop on the pre-
adjustment device.

Translation Page 46
 The preadjusted knives can then be mounted directly in the granulator.
Mounting a fixed blade Mounting a rotating blade
NOTE
All knife positions must be properly cleaned and free from oil, grease and dust.
Use a plastic or rubber mallet and knock/hammer the knives down and in against the rear of the
knife position.
Adjusting a fixed blade on the pre-adjustment device Adjusting a rotating blade on the pre-adjustment
device
ATTENTION
Before connecting the granulator, turn the rotor by hand to check the gap between moving and fixed
blades (to be sure they don’t hit each other).
Recommended gap 0.15 to 0.40 mm
10.4 Sharpening the knives

 Under normal operating use, the cutting edge of the knives will eventually become dull, resulting in
reduced cutting efficiency.

Translation Page 47
 The blunt knives may either be re-sharpened to restore the cutting edge or replaced with new knives
when re-sharpening is not possible.
 When sharpening it is not necessary to remove all small defects in the cutting edge.
 Perfect sharpening of the cutting edge is mostly not useful.All knives must be sharpened precisely to
give the correct cutting and relief angles otherwise the granulator loses its efficiency.
11 Cleaning
 Clean when changing colours or materials.
 Use a vacuum cleaner when cleaning the granulator, blow off with compressed air to remove all
remaining particles.
 Be careful when the hopper is open, the knives are exposed and could cause personal injury.
 Always use protective glasses and protective gloves during cleaning.
 Clean the inside of the hopper.
 Remove and clean the regrind collection bin.
 Clean inside the cutting chamber.
 Remove and clean the screen.
 Clean the outlet pipe.
Re-install after cleaning
WARNING
There is a risk to pinch his fingers when closing, be careful.
 Install the screen in its bracket and make sure it is over its complete periphery in contact with its
support.
 Close the screen bracket.
 Install the regrind collection bin, slide the bin on the guides and push it firmly against the stop.
 Clean the outside of the granulator.
 Close the hopper.
CAUTION
Hold the hopper carefully while closing.

Translation Page 48
Disconnect the granulator from the mains supply Take out the regrind bin
Lock the casters in place
Unlock the cutting chamber Swing open the hopper
Clean the granulator with a vacuum cleaner Open the screen bracket

Translation Page 49
Take out the screen Take out jammed particles from the holes using
compressed air or a screwdriver
Clean with a vacuum cleaner and a rag Put the screen back in
Close the screen bracket Slowly close the hopper
Lock the cutting chamber Put the cleaned bin back in again

Translation Page 50
Connect to the mains supply and start the Make sure it rotates in the direction of the arrow
granulator

Translation Page 51
12 Wiring diagrams
Two stickers are located on the inside of the door of the electrical cabinet.
The first sticker shows the item codes of the printed circuit board and the circuit diagram.
EBROY00___ Code printed circuit board
E-GMAX__ -V_-_-CN Refer to wiring diagrams
The second sticker shows the optional electrical devices added to the granulator and gives access to the circuit
diagrams of these options.
The circuit diagrams will be supply with the granulator.
13 Troubleshooting
This section identifies some of the most common issues involved with granulators and provides
recommendations to assist you in defining and answering your questions.
You may also contact your local Wittmann service department if your questions are not answered in the tables
below.
All troubleshooting must be accomplished with the power “Off”, the mains plug disconnected, and with the
granulator tagged as out of service.
The utmost in safety precautions should be observed at all times when working on or around the granulator
and the electrical components.
WARNING
Malfunctions and alarms must be diagnosed by specialized staff.

Translation Page 52
13.1 Electrical problems
Call for a qualified electrician for fault-finding and appropriate measures
Problem Possible cause Solution
Emergency push button Check that the emergency push button is

activated and locked unlocked
Review electrical installation and check that
No power voltage
the main disconnect switch is on “1” position
Check all safety switches, ensure proper
Safety switch not engaged or actuation (clean the closure surface) and
faulty (cutting chamber and adjust or replace as needed
screen bracket)
Motor does not start Caution: Never bypass a safety switch
Replace fuses with fuses of amperage and
Fuses are blown
type indicated on the circuit diagram
Motor protection circuit- Reset by electrician / technician
breaker tripped Check the overload circuit breaker inside
the electrical cabinet of the granulator.
Contact the Wittmann Customer service

Faulty motor components
centre
Motor is connected on 2
Review electrical installation
phases
Reduce amount / size of material put into
Excessive power the granulator
required: thermal relay Overloading of the granulator
Granulator capacity does not correspond to
activation or blown the required job
fuses
Blunt blades Re-sharpen or replace and re-install
Gap between fixed and
Adjust to proper gap specification
rotating knives too wide
Reduce amount / size of material put into
Overloading
the granulator
Granulator stalls
Clear the jammed material and clean and
Parts jammed in the rotor
empty the cutting chamber

Translation Page 53
13.2 Processing problems
Rotor is turning in the wrong Make sure it rotates in the direction of the
direction arrow
Material is crushed or Exchange 2 phases in the mains plug
drawn and not cut
Blades are blunt Replace or sharpen knives and re-install
Dusty Blades are blunt Re-sharpen or replace and re-install

The material is
electrostatically charged and Adjust the aspiration on the suction pipe
sticks to the sides of regrind Ground the bin to dissipate any electrostatic
collection bin charge
The evacuation is not Adjust the aspiration on the suction pipe

powerful enough
Use a more powerful system
Evacuating is not frequent
Change the diameter of the suction pipe
Regrind is not enough
completely evacuated Avoid elbows
Change the evacuation method (vacuum
system)
Increase the evacuating time
Increase the frequency of evacuation
Adjust the aspiration on the suction pipe

Material can be Ground the bin to dissipate any electrostatic
electrostatically charged, hot charge
Bridging of regrind in and rest above the outlet pipe
Add the cooling system option on the
the bin without being removed
cutting chamber
The material is too dusty
Re-sharpen the knives and and readjust the
gap between the blades
Material being placed into the Reduce the initial size of the sprues / parts
granulator for processing is
too large for the hopper or the Granulator capacity does not correspond to
Material hangs up in cutting chamber the required job
the hopper or cutting
chamber Regulate the material infeed to obtain a
Overloading
more uniform throughput
Knives are blunt Re-sharpen or replace and re-install
Transition tubing or suction

Clean as required
pipe is clogged
Granulate builds up in
regrind collection bin The aspiration system does Check the specifications of the aspiration
not work properly system, avoid elbows

Translation Page 54
Rotor turns in the wrong Make sure it rotates in the direction of the
direction arrow
Exchange 2 phases in the mains plug
Knives are dull Replace or sharpen knives and re-install
Reduce the initial size of the parts
Too much material is fed into Reduce amount / size of material put into
the granulator the granulator
Material warms up Granulator capacity does not correspond to
inside the cutting the required job
chamber
Increase cooling of parts before feeding

Material is too hot prior to Cool the material before feeding
being fed
Add the cooling system option on the
cutting chamber
Regrind is jammed into the Check the aspiration system

bin Feed the granulator more slowly

Translation Page 55
13.3 Transmission
Load exceeds the Check rated capacity of the motor and

Overloading
capacity of the motor reduce load
Position the belt correctly on the pulleys

Check the alignment and the geometry of
Runs hot Drive belt Not correctly positioned
the pulleys
Replace the belt if it is worn out
Insufficient lubrication
Bearing Clean or change the bearings
or penetration of dust
Inspect mounting of motor, tensioner and

Weak mounting pulleys.
structure Tighten loose bolts and/or reinforce
Loose bolts
mounting and structure
Bolts are loose Tighten bolts
Insufficient lubrication
Runs noisy Change the bearings
Failure of or penetration of dust
bearing Check rated capacity of the motor and
Overload
reduce load
Poor alignment of Check the position of the motor on the
pulleys supporting surface
Drive belt
Friction of belt on Spray some silicone onto the smooth outer
tensioner pulley surface of the belt
Parts are
broken or Broken belt Replace the belt
missing
Tensioning device not Check the mounting of the tensioner
working Change the tensioning device
Key of one of the
pulleys is missing or Replace the key
sheared off
The rotor is
not driven High load Feed the granulator more slowly
Overload Rotor is blocked due to

Turn “Off”, clean and empty the cutting
parts inside the cutting
chamber
chamber
Motor
Electrical problem See section 13.1
stopped

Translation Page 56
DANGER
Spray the silicone on the external side of the belt (in red)
Hide the internal side of the belt
Greasing can be done once the belt is mounted. In this case, hide the pulleys, as well as the inside
of the belt.
Lubrication on the inside of the belt, or on the pulleys, can cause slippage and therefore poor power
transmission between the motor and rotor. Too much slippage will result in rapid belt deterioration or
even breakage.

Translation Page 57
14 Customer service centre
Our Customer Service is available to assist you with technical problems, to answer your questions and to take
on your orders for spare parts, wear parts and kits.
The contact details of the subsidiaries and representatives of the WITTMANN figure on the website of the
Wittmann group http://wittmann-group.com , where you find the latest update.

Translation Page 58
15 Spare and wear parts
The list of the recommended spare and wear parts contains all the parts that be held on stock to keep your
Wittmann granulator in optimal running condition.
Always give the following information when ordering spare parts or contacting the Customer service centre:
 Item and serial number of the granulator as indicated on its name plate
 Item number of the circuit diagram as indicated on the sticker on the inside of the door of the electrical
cabinet
 Options installed on the granulator as indicated on the sticker on the inside of the door of the electrical
cabinet
 Number of the article or part concerned.
IMPORTANT
The granulator can be damaged when operating it with other parts as the original spare and wear parts
from Wittmann Battenfeld France.
NOTE
The parts of the electrical cabinet figure on the parts list on the circuit diagrams.

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15.1 Recommended spare parts list
Quantity of items
Item
G-Max G-Max G-Max
number
12 23 33
JFCAB018 12
Rotating knives
with screws
JFCEB018 6
JFCFB018 9
JFCAB017 2
Fixed knives
with screws JFCEB017 2
JFCFB017 4
Anti-wrapping
blade JFCFB019 2 2 2
with screws
JFCAB021 1
Drive belt JFCEB021 1
JFCFB021 1
Cutting chamber
JT012 2m 2m 2m
gasket

Translation Page 60
Screen
G-Max 12 G-Max 23 G-Max 33

diameter
JFCAB013 JFCEB013 JFCFB013
4mm
diameter
Screen with straight 5mm
holes diameter
6mm
diameter
8mm
diameter
4mm
Screen with conical diameter
holes 5mm
diameter
6mm
diameter
4mm
diameter
Screen with inclined 5mm
holes diameter
6mm
diameter
8mm

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15.2 Top priority spare parts
Quantity of items
Item number G- G- G-
Max12 Max23 Max33
DIV304 1
Drive belt
spanner
DIV324 1 1
DIV311 1
Tension roll
DIV312 1 1
MOT1.5017 1
Motor MOT3007 1
MOT4014 1
Capacitive
EW00001028 1 1 1
sensor
Key Safety AZ1516B12024

1 1 1
switch AZ16/12Z2RK

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15.3 Additional spare parts
Quantity of items
Item number G- G- G-
Max12 Max23 Max33
Gas spring VRG14009 1 1
Latch finger of
PG033 1 1 1
screen bracket
Ventilation filter of
DIV146 4 4 4
electrical cabinet
Flexible stop for

PLO2015 2 2 2
screen bracket
2 x RLET209
Caster kit 1 1 1
2 x RLET210
RLM0001 2
Bearings
RLM0002 2 2
Warning stickers AC042 1 1 1
Drive belt danger

AC046 1 1 1
sticker

Translation Page 63
Electrical danger
AC010A 1 1 1
Sticker
For the parts of the electrical cabinet see the parts list on the circuit diagram.
16. Parts and option kits

We recommend kits allowing to order under one item number :
- all the necessary wear parts for overhauling the granulator,
- additional functions for upgrades (see a description of the options in section 6.5.9).
16.1 Complete kit of cutting tool wear parts

Cutting tools wear parts Item number Content of the kit
JFCAB018 12 rotating knives with screws
G-Max 12 JFCAB017 2 fixed knives with screws
JFCAB019 2 anti-wrapping blades with screws
JFCEB018 6 rotating knives with screws
G-Max 23 JFCEB017 2 fixed knives with screws
JFCFB018 9 rotating knives with screws
G-Max 33 JFCFB017 4 fixed knives with screws

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16.2 Options kit
Options kit Item number Content of the kit
Pre-adjustment device for fixed and Instructions for pre-adjustment device
JFCEB020
rotating blades
Magnet
Magnet G-Max 12 JFCAB004 Fasteners
Screw fasteners
Magnet
Magnet G-Max 23 JFCEB004 Fasteners
Screw fasteners
Magnet
Magnet G-Max 33 JFCFB004 Fasteners
Screw fasteners
Fixed blade holder
Cooling system G-Max 12 JFCAB003 2 sealing couplings for connecting hoses of
inside diameter 10 mm
Fixed blade holder
Cooling system G-Max 23 JFCEB003 2 sealing couplings for connecting hoses of
Fixed blade holder
Cooling system G-Max 33 JFCFB003 2 sealing couplings for connecting hoses of
6m connecting cable + relay
Male and female connectors
Command for emptying the bin JFCAB028
Instructions with licence for software
activation of the function
6m connecting cable + relay
External On-Off of the granulator JFCAB029 Male and female connectors
instructions
Antistatic capacitive sensor JFCAB024 Replacement antistatic sensor

Translation Page 65

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OPERATION and INSTALLATION MANUAL

Conventional blade granulators G-Max 12 - 23 – 33

G-Max-V5.2-EN Operation and Installation Manual

G-Max-V5.2-EN Operation and Installation Manual

Serial number / Date / Model

Wittmann is committed to a continued program of product improvement.

Wittmann France SAS

G-Max-V5.2-EN Operation and Installation Manual

G-Max-V5.2-EN Operation and Installation Manual

1.2 Explanation of symbols

G-Max-V5.2-EN Operation and Installation Manual

1.4 Limits of liability

1.6 Customer service centre

G-Max-V5.2-EN Operation and Installation Manual

2.1 Intended usage

2.2 Changes and modifications

2.3 Emergency stop

G-Max-V5.2-EN Operation and Installation Manual

2.5 Duties of the personnel

2.6 Personal protective equipment

For particular tasks, additionally wear:

Light breathing protection

G-Max-V5.2-EN Operation and Installation Manual

Beware of electrical voltage

Check rotation direction

Do not introduce metallic parts

Do not insert body parts

G-Max-V5.2-EN Operation and Installation Manual

2.9 Safety system

G-Max-V5.2-EN Operation and Installation Manual

G-Max-V5.2-EN Operation and Installation Manual

3.1 In the event of shipping damage

3.2 If the shipment is not complete

3.3 If the shipment is not correct

G-Max-V5.2-EN Operation and Installation Manual

4.1 Granulator conditions at the receipt

G-Max-V5.2-EN Operation and Installation Manual

G-Max-V5.2-EN Operation and Installation Manual

5.1 Place of use

5.2 Electrical connection

G-Max-V5.2-EN Operation and Installation Manual

6.1 Functional description

G-Max-V5.2-EN Operation and Installation Manual

Conventional blade granulators G-Max 12 G-Max 23 G-Max 33

Motor output 1,5 kW 3 kW 4 kW

Rotor speed 200 rps - 50 Hz / 240 rps - 60 Hz

Fixed knives / blades 2 2 4

Rotating knives / blades 4x3 2x3 3x3

Double scissors cutting action ● ● ●

Diameter of cutting circle 180 mm 220 mm 220 mm

Hopper opening 252 x 155 mm 310 x 190 mm 453 x 190 mm

Cutting chamber 169 x 198 mm 310 x 235 mm 460 x 235 mm

Diameter of screen holes Standard 5 mm (conical holes)

Regrind bin volume 10 l 13 l 16 l

Throughput* 50 kg/h* 80 kg/h* 110 kg/h*

High level capacitive sensor for regrind ● ● ●

Electrical cabinet with “main disconnect switch”,

Machinery directive 2006/42/EC

Weight 220 kg 300 kg 340 kg

Drawings GM12910 GM23910 GM36910

G-Max-V5.2-EN Operation and Installation Manual

Granulator used for sound measurements G-Max 33

Serial number 16010