myBilding Formax FD 8902 User manual

Instruction Manual
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Formax FD 8902
Cross Cut Shredder

Shredder
FD 8902CC Cross-Cut
OPERATOR/
MAINTENANCE
MANUAL
SECOND EDITION
11/2007

The machine number is specifi ed on the nameplate on the shredder, shown above. Guarantee claims and
inquiries cannot be processed if you do not quote the machine number.
Enter this number and the other data into the relevant fi elds of the nameplate shown here immediately after
receipt of the shredder.
Machine Specs
Model: FD 8902CC
Serial #: __________________
Motor
7.5KW (10HP)
Power
220V / 60Hz / 3-Phase
Sheet Capacity
Up to 650 Sheets
Throat Width
21”
Weight
1,984 lbs.

TABLE OF CONTENTS
TOPIC
PAGE
Safety Precautions
1-2
Checking Safety Devices
3
Overview
4
Machine Characteristics
5
Cutting Data, Speed, Dimensions, Weight
5
Motor Specifi cations, Power Requirements
5
Installation
5
Installation: Space Requirements
6
Start-up: Main Switch and Control Panel
7
Operation, Oiling, Overloading
8
Emptying Waste Bin
9
Maintenance: Removing Side Covers
9
Maintenance: Conveyor Belt Maintenance
9-10
Maintenance: Lubricating Shredder Mechanisms
11
Maintenance: Exterior Cleaning
11
Parts Lists
12-19

“Work safety” symbol
This symbol marks all work safety notes in this manual which can endanger the health
or life of operators. Please pay attention to this symbol and exercise particular care in
such cases. Please also forward all work safety notes to other users.
Apart from the instructions in this manual, you should also follow generally
applicable safety and accident prevention guidelines.
Notes on work safety
The FD 8902CC shredder has been inspected for safety. However, improper operation and misuse risk the
following:
•
the health or life of the operator
•
the machine and other valuable equipment
•
the effi cient operation of the shredder.
The FD 8902CC employs state-of-the-art technology and is safe to operate. However, this machine can
become hazardous if used incorrectly, by untrained staff or for purposes other than those for which it is
designed.
•
Material with a tendency to curl, e.g. tapes, cords, etc. should not be processed.
•
Keep long hair, loose clothes, ties, scarves, etc. away from paper feed opening.
•
Only one person should operate the shredder at a time.
•
Always follow local safety and accident prevention regulations when operating the shredder.
•
No pedestals or other raised surfaces may be placed in the vicinity of the machine if they alter the
safety clearances.
•
All connecting cables must be laid in such a way that they cannot be tripped over.
•
Mechanical wearing parts must be inspected once a year.
“Attention” notes
This icon marks information in this manual which requires particular attention including
guidelines, regulations, instructions and correct working procedures intended to prevent
damage to the machine and/or other equipment.
Safety Precautions
Safety Precautions
1

2
The FD 8902CC shredder is intended for shredding paper, cardboard, archive fi les, tapes, ribbons, CDs and
magnetic disks. The hardened, solid-steel cutting rollers are unaffected by loose-leaf binders, paper clips and
staples contained in these materials.
Any other use beyond the scope described here is regarded
as
not being in
accordance with the
instructions.
The manufacturer will not be held liable for damage resulting from incorrect use; the user alone
is responsible.
Users must also follow the assembly, dismantling, re-assembly, operation and maintenance procedures
specifi ed by the manufacturer. The operation, maintenance and repair of the machine must be performed only
by trained personnel who are aware of the potential dangers.
The relevant accident prevention regulations as well as other generally recognized rules concerning safety
engineering and occupational safety must be observed.
•
Each person responsible for assembling, dismantling and reassembling and maintenance (inspection,
servicing, repair) of the shredder must have read and fully understood the entire operating manual, in
particular the "Safety" section.
•
The shredder may only be operated, serviced and repaired by authorized, trained personnel.
•
The shut-down procedures specifi ed in this manual must be followed during all assembly, dismantling
and re-assembling, cleaning, and maintenance work. This type of work must be performed only when
the machine is idle.
•
The drive of the FD 8902CC must be secured against unintentional switching-on before performing
work on the machine. Set the main switch to "Off" and unplug machine from wall outlet.
•
After repair, check all protective devices to be sure they have been re-installed before operation.
•
Do not perform any work which may impair your safety while operating the machine.
•
Immediately report any changes which impair your safety to the person responsible. Shut the machine
down until such damage has been resolved.
•
Before operating the shredder, ensure that it is in perfect working condition.
•
Ensure that the workplace around the FD 8902CC is always clean and safe.
•
The user must not make any conversions or changes on his own initiative which impair the safety of
the FD 8902CC. Protective devices must not be removed or rendered inoperative.
•
All work which is not directly connected to the normal operation of the machine must always be
performed when the machine is idle.
•
Doors and fl aps must not be opened until the machine is motionless. Observe safety labels!
•
Test the safety features after installing or repairing electrical components.

Checking the safety devices
Check the safety devices:
•
at the start of each work shift (when operation is sporadic)
•
at least once a week in continuous operation
•
after each maintenance or repair
Check the safety devices for:
•
specifi ed condition
•
specifi ed location
•
safe attachment
•
specifi ed function
Correct defects before you operate the shredder.
1. Immediately shut down the shredder if defects occur during operation and make sure the defects are
corrected.
2. Do not modify or remove protective devices. Do not switch off protective devices. For safety reasons,
modifi cations of the machine are not allowed.
Danger:
Defective safety devices can cause serious accidents. If safety devices are not
working properly, the shredder should immediately be put out of operation.
Never
reach into the cutting system while it is operating; you risk serious injury!
Only when all safety devices are operating correctly can the shredder be used again.
Operate the shredder only when these devices have been checked and are in order.
1. Check the
Safety Bar
push switch (A) in front of the feeding table:
Safety Bar push switch (A) in front of the feeding table: Safety Bar
The shredder must switch off immediately when you press the
Safety Bar
and the Emergency Stop
Safety Bar and the Emergency Stop Safety Bar
Light (B) must go on.
2. Check the
Emergency Stop
Button
(B) on
the left of the control panel:
The shredder must switch off immediately
when the button is pushed, and the
Emergency Stop Light must go on.
3. Check the
Safety Switch
inside the Cutting
Block Access Door at the top of the shredder
(C). Press the door handle release. Handle will
rotate up. Pull up on handle.
The shredder must switch off immediately
when the door is opened, and the
Emergency Stop Light must go on.
A
B
C
3

General Overview
Front View with Waste Bin
Control Panel
Feed Table
Safety Bar
Left Side View with
Electricity Control Box Access Door
4
Breaker Panel
Waste Bin
Control Panel
Infeed Conveyor
Infeed Conveyor
Waste Bin Latches
Waste Bin Latches

5
Machine characteristics
Machine designation: FD 8902CC
Machine type: conveyor-belt paper shredder
Total machine weight: 1,984 lbs.
Technical equipment: large feeding table, infeed conveyor belt
Cutting Data, Speed, Dimensions, Weight
Cutting Style:
Cross Cut
Shred Size:
5/16” x 1-1/2” - 3”
Sheet Capacity:
Up to 650
Speed:
Up to 35 feet per minute
Feed Opening:
21”
Dimensions:
47” W x 81” L x 63” H
Feed Table Dimensions:
47” W x 23.5” D x 49.5” H
Space Requirements:
79” W x 100.5” L x 118” H
Bin Capacity:
102 gal.
Weight:
1,984 lbs.
FD 8902CC
Motor Specifi cations, Power Requirements
Installation
1. Appropriate power receptacle must be available at installation site.
2. The FD 8902CC is delivered completely assembled (although it can be
delivered in parts, if necessary.) During transport, be aware of the
shredder’s high center of gravity.
3. The shredder can be moved on its casters. If a fork-lift is used to transport
the machine, be sure to use the designated pick-up points.
4. Install the shredder on a fl at and even fl oor without carpeting.
5. Once the shredder is in place, lock the caster brakes, and plug in power
cable to appropriate power source.
Motor Type
Horizontal Geared
Rated Power
7.5KW (10HP)
Operating Voltage
220/380V
Phase
3-Phase
Frequency
50/60Hz
Plug/Receptacle
CS8365 plug included
CS8369 receptacle required
Rated Current
25.5A/14.7A
Output RPM
25 RPM/35 RPM
Number of Poles
4
Total Rated Power Pn
7.5KW
Total Rated Current In
26A
Total Fuse Protection
35A
Power Plug

6
Installation
Space requirements for operation and maintenance
Left Side View
28 1/2”
47” (73” with door open)
81”

Control Panel
Start-up and Operation
Start-up and Operation
Main Switch
MODE/FULL/OPEN
INDICATORS
LED Displays
Lights signify mode (Auto/
Manual/Stop/Reverse) and
indicate when bin is full or
door is open.
REVERSE
Blue Touch Pad
Push button to reverse
direction of cutting blades.
EMERGENCY STOP
Red Push Button
Push button to stop cutting
system. Shredder remains
in standby mode until Start
button is pressed. (Shredder
can also be stopped by
pressing red Stop touch pad
on right of control panel or
large orange Safety Bar on
front of shredder.)
START A/M
Green Touch Pad
Push once to start Auto Mode: optical
sensors cause conveyor and cutting
blade to operate. Push twice to
choose Manual Mode: conveyor and
blades operate continuously.
OFF/ON
Key-Operated Toggle Switch
Turn key to right to turn
on cutting system.
Main Power Switch
Breaker Panel
Breaker Panel Interior
7
LOAD INDICATOR
LED Display
Displays load to provide maximum
capacity and avoid paper jams.

8
Operation
Operation
1. Set main switch to ON (page 7). Turn the Key OFF/ON toggle switch on the control panel to the ON position.
2. Press the START button. The conveyor will begin to move in the forward direction.
3. Place the material to be shredded on the feed table, then slide it onto the infeed conveyor belt, in
appropriate stacks. (Up to 650 sheets.)
NOTE: If material is accidentally placed onto the conveyor belt, DO NOT REACH FOR IT. Instead, press the
red STOP button (left side of control panel) or the Safety Stop Bar (front of feed table). When the shredder
stops, press and hold the REVERSE button. The conveyor will operate in reverse, allowing safer access to the
materials. The shredder will stop when the REVERSE button is released. To resume shredding, press STOP
button, then the START button.
Turning off the shredder
1. To shut down the shredder, press the STOP button on the control panel.
2. Turn Key OFF/ON toggle switch on the control panel to the OFF position (to the left).
3. Open the electrical control panel door, and fl ip the main power switch DOWN to the off position.
Overloading the motor
If the shred capacity of the machine is exceeded (too large a stack of paper, etc), the shredder will stop
automatically. To resume shredding:
1. Push and hold the REVERSE button until the paper or other material backs completely out of the shredder.
2. Press the red STOP button or the SAFETY BAR on the front of the machine, then divide the materials into
smaller stacks.
3. Press the START button. The conveyor and cutting blades will begin to move.
4. Continue shredding, feeding less paper or fewer materials at a time.
Frequent Overloading
If the shredder is repeatedly overloaded, the motor can overheat, which will cause the shredder to switch off
automatically. To resume shredding:
1. Allow the motor to cool down for approximately 20 - 30 minutes before using.
2. Once the motor has cooled suffi ciently, resume shredding by following standard operating procedure.
NOTE:
To maintain optimum performance and allow constant operation, avoid repeatedly
overloading the shredder. This will prevent time-consuming reversing cycles, and will
provide the highest possible throughput.
Oiling Cutting Blades with semiautomatic EvenFlow Oiling System
To keep the cutting blades in peak operating condition, Formax recommends using the EvenFlow Oiler prior to
the initial use, large shredding jobs, or whenever shred capacity appears to be decreased.
1. Open yellow screw-top cap on external pump assembly (see page 19). Fill with Formax 8902 shredder oil.
Do not fi ll above top red line on pump window. Replace cap.
2. To operate, pump the handle two to three times.

Emptying the Waste Bin
Shredded paper and particles accumulate in the shredder waste bin during normal operation. When the
“Waste Bin Full” lamp lights, empty the waste bin.
1. Switch the shredder off by pressing the STOP button on the control panel, turn the Key OFF/ON toggle
switch to the OFF position and fl ip the main power switch to the OFF position.
2. Grasp handle on waste bin and pull straight out. Gather sides of shredder bag using drawstring. Flip open
two latches on front left of waste bin (see page 4), swing open door and slide bag out. Close and latch door.
Empty and replace bag.
3. Push the waste bin in, turn power switches back on and resume shredding.
Maintenance and Inspection
Maintenance and Inspection
9
Conveyor Belt Maintenance
•
Checking Belt Tension
When loaded with material, the conveyor belt must not slip, i.e. stand still when material is loaded. If the
belt slips, it must be tightened. Contact the Formax Service Department for assistance.
•
Checking Belt for Wear
The upper surface of the conveyor belt can become worn over time. The belt must be replaced when
the woven fabric inlay becomes visible. Contact the Formax Service Department for assistance.
•
Cleaning the Conveyor Belt area
The conveyor belt area must be cleaned once a month, or as needed to maintain optimal performance.
1. Switch off the shredder and unplug from wall outlet.
2. Remove the covers on both sides, revealing the cleaning openings in the conveyor belt area.
3. Use compressed air to blow out particles, or a vacuum to remove dirt and dust.
4. Re-install side covers.
NOTE: Paper clips in the shredded materials may increase the frequency of cleaning necessary, and may
become caught in the sides of the belt.
Removing & Reinstalling Side Covers
Side covers are each attached by three Phillips head
screws.
1. To remove covers, insert screwdriver through access
holes (Fig. 1), and remove screws. Lift covers off
frame hooks.
2. To reinstall, rest panels on hooks, replace screws.
NOTE: The maintenance procedures which follow should be
performed only by authorized and trained technicians.
Figure 1

10
•
Cleaning the Conveyor Belt Tensioning Station
The tensioning station must be cleaned once a month, or
as needed to maintain optimal performance.
1. Switch off the shredder and unplug from wall outlet.
2. Remove the feed table and front panel of tensioning
station (Fig. 2).
3. Remove particles and dirt.
4. Re-install the feed table and front panel of tensioning
station.
Tensioning station adjuster
Fig. 2
•
Checking the Cutting Head Chain Tension
Check the chain tension once every week in the fi rst month, then once a month thereafter.
1. Switch off the shredder and unplug from wall outlet.
2. Remove the top right side cover.
3. The sagging of the chain (see Fig. 3) should be 9 - 14 mm, measured from the top inside of
the frame to the cutting head chain.
If it is not within this range, loosen the tension screws until the sagging reaches the
correct level. Retighten the tension nuts.
4. Replace the side cover, plug in the shredder.
NOTE:
Excessive tensioning of the chain can cause premature wear of the chain and bearings.
The smallest allowed chain sagging in the fi rst month of operation is 5 mm. After that, 9 mm.
Fig. 3
Underside View of Feed Table
and Infeed Conveyor

11
Exterior cleaning
•
Turn shredder off and unplug from wall outlet.
•
Wipe the exterior surfaces with a soft cloth. If the surfaces are 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.
Lubricating Shredder Mechanisms
•
Cutting System:
The cutting system should be oiled once a month or as needed for optimal performance.
1. Open the Cutting Block Access Door on the top of the shredder. Press latch and the handle
will spin around. Pull up on the handle.
2. Spray special cutting block oil through the paper inlet, onto the cutter rolls.
3. Close the Access Door and press the START button on the control panel.
4. Run the cutting system forward and backward several times,
without feeding paper
. This will
help to remove paper shreds and particles.
A
•
Drive Chains:
The drive chains should be checked during PMs,
and greased as needed.
1. Switch off the shredder and unplug from wall
outlet.
2. Remove both top side covers.
3. Grease the cutting system conveyor belt
drive chain (A) and the motor cutting system
drive chain (B).
4. Replace side covers and plug in shredder.
B
•
Synchronizing Wheels:
1. Switch off the shredder and unplug from wall
outlet.
2. Remove left top side cover.
3. Grease the synchronizing toothed wheel (C).
4. Replace side cover and plug in shredder.
C
Right Side
Left Side

12
PARTS LISTS
ITEM
PART #
DESCRIPTION
QTY
1
8902-TOP-01
TOP CASE
1
2
8902-TOP-02
LOADING TABLE
1
3
8902-TOP-0
3
UPPER FRAME (LEFT, RIGHT)
1 ea
4
8902-CON-01
CONVEYOR BELT ASSEMBLY
1
5
8902-BEL-01
CONVEYOR BELT
1
6
8902-BEL-02
CLEAR PLASTIC SAFETY STRIP
1
7
8902-TOP-05
FRONT CASE
1
8
8902-TOP-06L
LOADING TABLE SUPPORTER, LEFT
1
9
8902-TOP-06R
LOADING TABLE SUPPORTER, RIGHT
1
10
8902-WST-01
WASTE BIN
1
11
8902-TOP-07
CUTTING HEAD ACCESS DOOR
1
12
8802-BOL-01
LOADING TABLE SUPPORTER BOLTS
22
13
8902-TOP-04
REAR CASE
1
14
8902-BOD-01
LOWER FRAME
1
15
8902-BOD-02
REAR CASE, LOWER
1
16
8902-PCB-13
PCB COVER
1
17
8902-PCB-14
PHOTO-EYE SENSOR
1
18
8902-OIL-22
EVENFLOW OILER PUMP ASSEMBLY
1
Rear View
3
3
14
15
Power Cord Input
13
2
3
7
1
4
5
6
8
Front View
12
3
9
10
11
16
17
17
18

ITEM
PART #
DESCRIPTION
QTY
1
8902-BOD-04
UPPER SIDE CASE, LEFT
1
2
8902-BOD-06
LOWER SIDE CASE, LEFT
1
3
8902-TOP-07
CUTTING HEAD ACCESS DOOR
1
4
8802-PCB-07
MICRO SWITCH, ACCESS DOOR
1
5
8902-TOP-02
LOADING TABLE
1
6
8902-TOP-06L
LOADING TABLE SUPPORTER, LEFT
1
7
8902-TOP-06R
LOADING TABLE SUPPORTER, RIGHT
1
8
8902-PCB-02
ELECTRICITY CONTROL BOX DOOR
1
9
8902-CAT-01
BODY CASTERS
4
10
8902-BOD-03
UPPER SIDE CASE, RIGHT
1
11
8902-BOD-05
LOWER SIDE CASE, RIGHT
1
12
8902-OIL-22
EVENFLOW OILER PUMP ASSEMBLY
1
13
Left Side
1
2
3
4
5
8
6
8
Right Side
10
9
11
5
7
12

14
ITEM
PART #
DESCRIPTION
QTY
1
8902-WST-01
WASTE BIN
1
2
8902-WST-02
WASTE BIN DOOR LATCHES
2
3
8902-WST-03
WASTE BIN CASTERS
4
4
8000-95
NYLON
WASTE BIN BAG
2
5
8902-WST-04
WASTE BIN DOOR CASTER
1
6
8902-WST-05
WASTE BIN DOOR HANDLE
1
7
8902-WST-06
WASTE BIN DOOR
1
8
8902-WST-07
WASTE BIN DOOR HINGES
2
WASTE BIN (FD 8902
WASTE BIN (FD 8902
CC)
CC)
1
2
3
8
7
5
6
4

15
ITEM
PART #
DESCRIPTION
QTY
1
8902-CTB-02
SIDE PLATE, RIGHT
1
2
8902-CTB-01
SIDE PLATE, LEFT
1
3
8902-CTB-07
LONG SHAFT
1
4
8902-GEA-01
GEAR
1
5
8902-SPR-03
MOTOR SPROCKET
1
6
8902-MOT-01
MOTOR (220V, 60Hz, 10HP)
1
7
8902-CCH-01
CUTTING HEAD CHAIN
1
8
8902-RUB-01
VIBRATION-PROOF RUBBER (100)
4
9
8902-CTB-08
SHORT SHAFT
1
10
8902-SPR-01
CONVEYOR SPROCKET
1
11
8902-CON-03R
CONVEYOR BELT BRACKET, RIGHT
1
12
8902-CON-03L
CONVEYOR BELT BRACKET, LEFT
1
13
8902-CCH-02
CONVEYOR CHAIN
1
14
8902-SPR-02
CONVEYOR DRIVE SPROCKET
1
-
8902-CTB-00
CUTTING HEAD
Left Side
Right Side
CUTTING HEAD
1
6
16
10
7
8
5
10
3
11
13
9
2
15
6
14
3
12
4
8
9

16
ITEM
PART #
DESCRIPTION
QTY
1
8902-MOT-01
MOTOR (22OV, 60Hz, 10HP)
1
2
8902-CTB-20
WASTE GUIDE, REAR
1
3
8902-CTB-21
MICRO SWITCH, WASTE BIN FULL SENSOR, 15A
1
4
8902-PCB-10
POWER PLUG
1
5
8902-PCB-15
ELECTRICITY CONTROL BOX COVER
1
6
8902-PCB-00
ELECTRICITY CONTROL ASSEMBLY
1
7
8902-PCB-05
WIRE TERMINAL PLATE
1
8
8902-PCB-09
BREAKER
1
9
8902-PCB-06
MAGNETIC CORE
2
10
8902-PCB-03
ELECTRICITY CONTROL BOX
1
11
8902-PCB-04
EOCR
1
12
8902-PCB-01
ELECTRICITY CONTROL BOX BASE
1
1
10
2
9
5
6
3
ELECTRICAL
4
8
7
11
12