Formax FD 8502AF User manual

FD 8502AF
AutoFeed Shredder
MAINTENANCE MANUAL
FIRST EDITION
11/2013

TABLE OF CONTENTS
TOPIC PAGE
Specications 1
Set-up Guidelines 1
Control Panel 1
Operation 2
AutoFeed Operation 2
Safety Devices & Other Features 3
Safety Precautions 3
Daily Maintenance 4
Auto Cleaning 4
Sensor Sensitivity Recovery 4
Removing Motor & Cutting Head Unit 4
Replacing Door Hinges 5
Replacing Casters 5
Repairing Motor Condenser & Contactor 5
Adjusting Feed Hopper 6
Troubleshooting 7-8
Parts Lists 9-13
Electrical Parts 14-15

1
Set-up Guidelines
1. Install the shredder on a level surface, away from heat sources and direct sunlight.
2. Insert plug into wall outlet with the appropriate voltage, 110V. If the outlet is shared with another electronic device, the
total current should not exceed 30A (at 110V).
Specications
Cutting Style: Cross Cut
Shred Size: 5/32” x 1-1/5”
AutoFeed Hopper: Up to 175 sheets
Hand-Feed Hopper: 22 to 24 sheets
Speed: 35 feet per minute
Feed Opening: 16” (hand-feed hopper)
Dimensions: 24” W x 20” D x 35” H
Security Level: Level 3
Bin Capacity: 26 gal.
Weight: 242 lbs.
Power supply: 110V, 50/60 Hz
Accepts credit cards, staples and paper clips in hand-feed hopper
Control Panel
Control Panel Functions
AUTO: The shredder will operate in Auto mode after pressing the Start button.
MANUAL: By pressing the Start button a second time, the shredder can be operated
in Manual mode. The shredder will begin running, and will stop automatically after 3
minutes.
REV: The shredder will automatically reverse cutter direction if too many sheets of
paper are inserted at one time.
FULL: The shredder automatically stops when the waste bin is full.
LOAD INDICATOR: This multi-colored indicator shows the load during shredding.
OPEN: The shredder will stop automatically if the cabinet door is open. Simply close
the door and press Start to resume operation.
STOP: Pressing this button stops operation.
REV. BUTTON: Pressing this button reverses the cutting blades.

2
Operation
1. Flip the power switch “ON” located on the right side of the shredder.
2. Auto Start/Auto Stop
When the START button is pushed, the signal lamp “AUTO” will light. Insert paper to shred. The shredder will start and
stop automatically when using this function.
3. Manual Operation
If paper is too small for the shredder’s sensors to detect, shred it manually. Push the START button once more and the
“MANUAL” lamp will light. Insert paper to be shredded. Three minutes after shredding, the cutter automatically stops
rotating.
4. Reverse Operation
Push the REV button and the signal lamp “REV” will light and cutters will operate in reverse. If too much paper is inserted
at one time in standard modes, the shredder will automatically operate in reverse. If this occurs, remove the inserted
paper and shred in smaller amounts. NOTE: The maximum amount of paper to be shredded differs according to paper
quality, humidity and voltage. If the shredder is to be used continuously, do not insert more than half of the maximum
capacity.
5. Full Sensor
If the waste bin is full, the “FULL” lamp will light and the cutter will stop automatically. Open the door, empty the waste bin
of paper scraps, replace the waste bin, close door, and continue to shred.
AutoFeed Operation AutoFeed
Hopper Lid
1. To use the AutoFeed Hopper, press “Start” to enter Auto Mode.
2. Lift open AutoFeed Hopper Lid.
3. Press down AutoFeed Lever and load up to 175 sheets of paper to be
shredded. Release lever.
NOTE: Load 8.5” x 11” paper landscape and 8.5” x 14” and 11” x 17”
paper portrait.
NOTE: Feeder does not accept staples or paper clips.
4. Paper will automatically feed and be shredded. Cutting blades will stop
after shredding is complete.
5. Close lid when AutoFeed Hopper is not in use.
AutoFeed
Lever

Safety Devices & Other Features
Automatic Reverse Rotation
When too much paper is inserted, the cutter stops operating and automatically rotates in reverse to discharge the jammed
paper. An alarm sounds. Remove the jammed paper and reduce the size of the stack, then restart the operation.
Door Switch
If the door is open, the shredder will not operate.
Automatic Stop
When the waste bin is full of shredded paper, the “FULL” LED will light comes on and the cutter stops operation. Open the
door, remove the waste bin and empty paper scraps. Replace the waste bin, close the door and continue operation.
Automatic Power Shut-Off
• If the shredder operates continuously for more than 30 minutes, the power is automatically shut off.
• If the motor is overloaded, the “STOP” LED will ash until it cools down. When the ashing stops the shredder is ready
to be used again.
Oil Indicator
The “MANUAL” LED will ash after every four (4) hours of operation as an indicator to oil the shredder cutting blades. The
LED will continue to ash until oiled. NOTE: the shedder will still operate when the LED is ashing but at a decreased
load capacity.
To oil: Spread shredder oil onto the cutters through the feed opening, and allow the oil to sit for a few minutes to
permeate the cutting blades, then press the “REV” button and hold for ve seconds. “MANUAL” and “REV” LED indicators
on control panel will light. The shredder will operate in reverse for one minute, then the “AUTO” LED will light indicating
the shredder is ready.
3
Safety Precautions
To avoid personal injury, and damage to the shredder, observe the following safety precautions. Please keep these
instructions for future reference.
NOTE: In case of emergency, ip the “Power Switch” to cut off power
and/or pull the plug out of the wall outlet.
•Keep hands, long hair, clothing, ties, jewelry and loose items away from the
feed opening and shred outlet.
•Do not use the shredder for anything other than its intended purpose. Never
use it to shred cloth, plastic, cardboard or any hard material that will cause
damage to the shredder blades.
•Do not allow children to use the machine.
•Do not operate with a damaged power cord or plug, or when the machine is
damaged in any manner.
•Unplug the shredder when it is being moved, or if it is not in use for an
extended period of time.
•Do not disconnect the power by pulling only the cord. Hold the plug when
disconnecting.
•Keep the shredder away from direct sunlight.
•Do not sit on the shredder or place anything on top of it.
•Never open the xed switch or cover.

4
Over time, the shredder photo eye may lose its sensitivity. Use the following steps to reset the sensor’s sensitivity.
1. If the sensor cannot detect paper:
• Press the Stop button for ve seconds.
2. If the shredder is operating without paper in the feed opening:
• Press stop, then insert paper into the feed opening and press the Stop button for ve seconds.
After following either of these steps, all LED lamps should be off, and the shredder will make a beep sound. Sensitivity is
recovered and the shredder is ready to operate. Follow instructions under Operation.
Sensor Sensitivity Recovery Function
To remove the motor and cutting head unit for servicing:
• Open front door, remove screws connecting lid to
body case.
• Unplug cables and remove lid; set aside.
• Remove waste bin; set aside.
• Using a 12mm socket, remove four nuts on under side
(see Figure 1).
• Carefully lift out motor/cutting head unit from the top.
CAUTION: Heavy.
Removing Motor & Cutting Head Unit
Figure 1
Use the Auto Cleaning function when sheet capacity is decreased.
1. Prior to using the Auto Cleaning function, spread shredder oil onto the cutters through the feed opening, and allow the
oil to sit for a few minutes to permeate the cutting blades.
2. Press the REV button and hold for ve seconds. Manual and Rev LED indicators on control panel will light.
3. The shredder will operate in reverse for one minute, then the Auto LED will light.
Auto Cleaning Function
• Disconnect power by removing the power cord plug from wall outlet.
• To clean the exterior, wipe the surface with a soft cloth. If the surface is very dirty, use a neutral detergent, then wipe
again with a soft cloth.
CAUTION:
• Never put water directly on the surface of the shredder.
• Never clean the case with benzene or thinner, since it will cause discoloration.
• Do not dismantle the shredder. Contact your Formax Dealer for service.
Daily Maintenance

5
If the door is separated from the body housing, replace the upper and/or lower hinge, (Figures 2 and 3).
Replacing Door Hinges
Figure 2, top hinge Figure 3, bottom hinge
If casters are damaged, remove rivets and attach new casters with
screw bolts (Figure 4).
Replacing Casters
Figure 4, caster
If the motor doesn’t work, the motor condenser or motor current contactor could be damaged. Open the motor cover,
clean the contactor and adjust the gap of contactor.
Alternately, replace the motor condenser.
Repairing Motor Condenser & Contactor
Reduction geared part of motor
Motor current contactor

6
Adjusting the AutoFeed Hopper Guide
1. Remove top case assembly.
2. Press AutoFeed Lever and slide in a stack of 8 sheets
of 20# paper (Figure 5).
Figure 5
Figure 6
Figure 7
The AutoFeed Hopper Guide is set at the factory. However, if paper is feeding incorrectly or too many sheets are being
pulled causing the shredder to jam, it may be necessary to adjust the infeed gap.
3. To adjust Hopper Guide up or down, use a 5.5 mm nut
driver to loosen the 4 screws holding it in place (Figure
6).
Hopper Guide
AutoFeed Lever
4. Press down on the Guide and slide the paper in and
out until you reach medium to light drag on the paper
stack (Figure 7).
5. Tighten screws and replace Top Case.

7
TROUBLESHOOTING
PROBLEM: CHECK THIS: SOLUTION:
Shredder will not operate Check that the power cord is plugged
into an appropriate outlet
Plug cord into outlet
Check voltage of power outlet If necessary, nd an alternate outlet with the
appropriate voltage
Check the wiring between the fuse con-
nector on the PCB (page 14)
Reconnect, if necessary
Shredder capacity is decreased Follow directions for Auto Cleaning, page 4
Main power is functioning but
shredder won’t operate (Main
PCB)
Check main power cable (page 14) to
see if it is properly connected to the
Main PCB (page 14)
Reconnect, if necessary
Check the Main PCB’s printed circuit
and wire disconnection of transformer
If there is a problem with the circuit and/or
transformer, replace with new one
Check the electrical contacts on the
main control switch
Reconnect, if necessary
Main power is okay, but shred-
der is not working (electrical)
NOTE: Photo sensor should be
connected with the main PCB
during testing.
Check the outlet for correct voltage,
120V
Use different outlet, if necessary
Check wire connection between photo
sensor and Main PCB (pages 14 & 15).
If there is no output signal from Main
PCB, shredder will not operate.
Reconnect cable to sensor and Main PCB
Photo sensor could be dirty Remove photo sensor (page 14) and clean
it with a soft cloth
Photo sensor sensitivity may need to be
reset
Sensitivity measurement distance should be
.4 inch (10mm). If distance is less than .4
inch, replace the photo sensor
Check power relay contacts Reconnect, or replace main PCB power
relay if necessary. If printed circuit is dam-
aged, replace the main PCB.
Main power is okay, but shred-
der is not working (mechanical)
Check motor current contactor Open motor cover, clean contactor and
adjust gap of contactor (page 5)
Shredder may have overheated. Wait 5-10 minutes for motor to cool down,
then resume shredding
Check motor condenser for damage Replace motor condenser

Shredder motor and blades
continue to rotate
Check control panel lights to see if
AUTO lamp is ashing
If so, follow instructions for Sensor
Sensitivity Recovery (page 4)
Check control panel lights to see if
MANUAL lamp is on
If yes, press the START button. AUTO lamp
should light and shredder should operate in
AUTO mode.
Photo sensor could be dirty Remove photo sensor (page 14) and clean
it with a soft cloth
Photo sensor sensitivity may need to be
reset
Sensitivity measurement distance should be
.4 inch (10mm). If distance is less than .4
inch, replace the photo sensor
Check power relay contacts Reconnect, or replace main PCB power
relay if necessary
Reverse function will not work Check power relay contacts (in case of
electrical coil damage)
Replace power relay
Check printed circuit for damage If damaged, replace the Main PCB
Shredder makes an unusual or
metallic noise
Check cutters for materials lodged be-
tween cutting blades and/or guides
If so, turn off shredder and carefully remove
any foreign materials from the cutter. Then
follow instructions for Auto Cleaning (page
4)
Check guides and cutters for damage
(pages 10& 11)
If guides and/or cutters are broken, the
whole cutting head should be replaced
Check bearings, space rings and cut-
ting shafts for damage (pages 10 & 11)
If any of these parts are damaged, they
should be replaced, in addition to side
plates
Motor makes a “tick tick” noise Check the reduction gears for damage
(page 5)
If the reduction gears are broken,
replace the entire motor
8

9
PARTS LISTS
ITEM PART # DESCRIPTION QTY
* FD8502AF-CAS-01 TOP CASE ASSEMBLY 1
1 FD8502AF-CAS-02 TOP COVER 1
2 7410-BOD-01 BODY CASE 1
3 7310-BOD-02 UPPER DOOR HINGE 1
4 7310-BOD-03 LOWER DOOR HINGE 1
5 7410-DOR-01 DOOR 1
6 7310-DOR-02 DOOR MAGNET 1
7 7410-FRT-01 FRONT COVER PLATE 1
8 WST-AA-0006 WASTE BIN 1
9 7310-ELE-03 MICRO SWITCH, DOOR, 15A (INTERNAL) 1
10 7310-CAT-01 CASTERS 4
1
93
5
4
10
8
6
7
2

MECHANICAL PARTS
ITEM PART # DESCRIPTION QTY
1 FD8500AF-CTB-03 MOTOR, 400W 1
2 7410-GEA-04 SPUR GEAR (m=2, z=31) 1
3 7410-GEA-03 SPUR GEAR (m=2, z=31) 1
4 7410-GEA-02 MAIN SPUR GEAR (m=2, z=59) 1
5 7410-GEA-01 MOTOR GEAR (m=2, z=59) 1
6 7310-ELE-01 CIRCUIT BREAKER, 15A 1
7 7310-ELE-03 MICRO SWITCH (DOOR), 15A 1
8 FD8500AF-CTB-04 SIDE PLATE, LEFT 1
9 FD8500AF-CTB-05 SIDE PLATE, RIGHT 1
10 7410-CTB-04 POST 2
11 7410-CTB-05 FRONT WASTEPROOF PLATE 1
12 7410-CTB-06 MIDDLE PLATE 1
13 7410-CTB-07 SHAFT (LONG) 1
14 7410-CTB-08 SHAFT (SHORT) 1
15 7410-CTB-09 CUTTER BLADE -
16 7410-CTB-10 GUIDE -
17 7410-CTB-11 RING -
18 7310-CTB-12 BEARING (6005ZZ) 2
19 7410-CTB-13 SPACE RING ACETAL (3.0t) -
20 7410-CTB-14 SPACE RING ACETAL (5.0t) -
21 7410-CTB-15 BEARING WASHER (AW 06) 1
22 7410-CTB-16 BEARING NUT (AN 06) 1
23 7310-PCB-01 MAIN PCB 1
24 7310-PCB-03 MAIN PCB COVER 1
25 ELE-AA-0021 MOTOR CONDENSER 1
- 7410-CTB-00 CUTTING HEAD WITH MOTOR -
- 7410-CTB-01 CUTTING HEAD WITHOUT MOTOR -
12 1
6, 7
23, 24
10
9
11
13
14
8
2
5
4
3
22
18
19, 20
(not visible)
16
15
21
17
(not visible)
25
10

11
4
ITEM PART # DESCRIPTION QTY
1 7310-RUB-01 VIBRATION-PROOF RUBBER 4
2 7310-FUL-01 WASTE BIN FULL SENSOR PLATE 1
3 7310-ELE-02 MICRO SWITCH (WASTE BIN) 1
4 7310-FIL-01 NOISE FILTER 1
2
3
Underside View
1
Underside View
Top View

12
ITEM PART # DESCRIPTION QTY
* FD8502AF-CAS-01 TOP CASE ASSEMBLY *
1 FD8502AF-CAS-02 TOP CASE 1
* FD8502AF-CAS-03 AUTOFEED COVER ASSEMBLY *
2 FD8502AF-CAS-04 AUTOFEED COVER TOP PANEL 1
3 FD8502AF-CAS-05 AUTOFEED COVER BOTTOM PANEL 1
4 FD8502AF-CAS-06 AUTOFEED ROD 1
5 FD8502AF-CAS-07 AUTOFEED SCREWS 8
6 FD8502AF-CAS-08 FEED COVER E-RING 2
7 FD8502AF-CAS-25 AUTOFEED COVER HANDLE 1
8 FD8502AF-CAS-26 AUTOFEED COVER HANDLE SCREWS 2
AUTOFEED COVER
ASSEMBLY
1
4
3
6
2
7
5
AUTOFEED
SENSOR
HAND-FEED
SENSOR
8

13
ITEM PART # DESCRIPTION QTY
* FD8502AF-AF-01 AUTOFEED HOPPER ASSEMBLY *
1 FD8502AF-AF-02 AUTOFEED HOPPER 1
2 FD8502AF-AF-03 AUTOFEED TRAY 1
3 FD8500AF-AF-13 SPRING 2
4 FD8500AF-AF-04 AUTOFEED BRACKET 1
5 FD8500AF-AF-09 AUTOFEED SHAFT 1
6 FD8500AF-AF-08 AUTOFEED ROLLERS 3
7 FD8500AF-AF-06 AUTOFEED GUIDE 1
8 FD8500AF-AF-07 BEARING 2
9 FD8500AF-AF-10 SPROCKET A 1
10 FD8500AF-AF-11 SPROCKET B 1
11 FD8500AF-AF-12 CHAIN 40# 1
12 FD8500AF-AF-05 FEED BLOCK 1
1
3
5
4
2
76
8
9 10 11
12

14
ITEM PART # DESCRIPTION QTY
1 7310-PCB-02 SWITCH PCB 1
2 7410-TOP-02 SWITCH PCB COVER 1
3 7310-PCB-04 PCB SUPPORTER (JOSS-6N) 4
4 7310-SEN-01 PHOTO EYE SENSOR 1
5 FD8500AF-PCB-01 SENSOR HARNESS 1
6 7310-ELE-05 BODY CABLE 1
7 7310-ELE-09 POWER PLUG 1
87410-THR-01 INFEED THROAT 1
ELECTRICAL PARTS
1, 2
45
3
7
1
6
8

15
ITEM PART # DESCRIPTION QTY
1 7310-PCB-01 MAIN PCB 1
2 7310-ELE-01 MAIN POWER SWITCH/CIRCUIT BREAKER, 15A 1
3 7310-ELE-03 MICRO SWITCH (DOOR), 15A 1
4 7310-ELE-06 MAIN CABLE 1
5 7310-ELE-07 DATA OUTPUT CABLE 1
6 7310-ELE-08 DOOR FULL CABLE 1
7 7310-TRA-01 TRANSFORMER 1
8 7310-PCB-03 MAIN PCB COVER 1
7
2
5
(external
connection)
3
1
4
2
3
Inside View
5
6
8