1.0 INTRODUCTION This service manual covers adjustment
Contents
1. 0 5 SIYHIMS TOMAS pa Beg s 8405095 HAH DB gon Pal ZEA MPA TEA 099282. Complete Section 6 5 Motor Chassis Removal 5 Remove two 13mm hex head bolts opposite of the motor side from support bars 6 Remove the bag full spring 7 Remove four 15mm lock nuts from left hand side frame 8 Remove plastic deflectors from the cutting head 9 Remove side support bracket from left hand side Sharp Objects Gloves must be worn before proceeding 10 Carefully Maneuver cutting head assembly out towards motor side 11 Remove three side plate supports and shims from each side cutter assembly 12 Separated cutters 13 Slide the four cross support bars out from the strippers 14 Slide strippers and fillers out from the cutters 6 0 DISASSEMBLY ASSEMBLY ADJUSTMENTS 6 7 1 The shredder is easily assembled by following the disassembly instructions in the reverse order 2 The cutter gears must be timed before installing the chain 6 8 Cutter Timing Before installing the cutter gears check the cutter shaft key ways to ensure that they are in series Figure 6 1 Slight rotation of the cutter gears may be necessary to align the teeth of the gears when installing Before installing the drive chain test by manually shredding one sheet of paper Failure to align the cutters as shown in Figure 6 1 will result in incomplete shredding and reduced shred capacity Figure 6 1 7 0 PROCEDURES 7 1 Cleaning Make sure you d
3. required for the below installation procedure 1 Using the hand grips a provided figure 1 place the machine head into the top of the cabinet The control panel may face toward the front or back of the cabinet 2 Open the door by pressing on the door knob and place the hand grips a located in the cabinet base b figure 2 into the holes found in the cabinet 3 Insert a plastic bag into the bag frame from the under side of the rail fold over all four sides and slide back into the guide rails 4 Connect the power cord to a single phase socket rated at 15 amps Figure 2 4 0 OPERATING INSTRUCTIONS The GBC 5160X shredder can shred most office paper and documents However the shredding of paper clips and other metal items may cause damage to the shredder Plastic materials such as credit cards covers inserts and film should be avoided as they may lodge in the cutting head and prematurely dull the cutters Operation Please refer to the shredder control panel shown in Figure 4 1 1 To begin using the shredder press the rocker switch a to the on position The green control light b will illuminate The shredder is now in the stand by mode and will automatically start shredding when paper is inserted When shredding is complete the machine will automatically stop and return to the stand by mode 2 If the bag full control light c is on the shredder bag must be changed 3 For safety concer
4. when depressed connects the hot and neutral circuits to electrical components of the shredder Machine Head Safety Sensors The safety sensors are both normally open hall effect switches which are actuated by a magnet inside of the cabinet door and the back panel of the cabinet The switches are normally closed when the door is closed and when the machine head is installed on the cabinet Flap Switch The flap switch is a normally open switch actuated by the bag full flap When the shred bag becomes full of shredded material the bag full flap is pushed back and power is then removed from the motor circuit Emitter The infrared light beam from the light emitting diode is sensed by the receiver to activate deactivate the control board Receiver The receiver is a light activated diode which works in conjunction with the emitter to activate deactivate the control board Door Bag and Reverse Indicators These LED s illuminate when the following condition occurs When the door is open the shred bag is full or when the shredder is jammed 5 4 Testing Electrical Components E INWARNING Always disconnect the power cord from receptacle before making continuity or resistance tests Switches Set meter to read resistance Check switches for continuity from common to closed contacts and infinity from common to the open contact Emitter Set meter to the diode setting Disconnect emitters from the control boar
5. 182 5160 PARTS LIST FIGURE 8 5 ge mE 9001 392 4000 733 220 240V 4000 734 100 120 9003 386 220 240 9001 264 100 120 9001 263 100 120 9001 565 9001 412 9001371 9001 562 9002 349 9001 412 9001 020 4000 732 220 240 4000 731 100 120 Ga 9003 286 20 21 5160 PARTS LIST FIGURE 8 6 690 00 262 006 906 1006 061 2006 SERVICE MANUAL MODEL 5160X 6160X CROSS CUT SHREDDER Binding Corpordtion One GBC Plaza Northbrook 60662 General Binding corporation Issued 08 00 10 5160X WIRING DIGRAM 212 5504 X091S JDUDEGE7 ze IS JojDede 7 indu 2109 ASH N 14 Frag HE Ip em EREF PREE 1005 9 9 z EFE N p
6. 1 0 INTRODUCTION This service manual covers adjustment disassembly operation preventative maintenance troubleshooting procedures and contains an illustrated parts list for the GBC Shredmaster 5160x shredder The GBC Shredmaster 5160x is a cross cut console shredder designed for higher volume requirements Begining mid year 1997 the 5160x will be renamed as the 6160x The 6160x is identical to the 5160x with the exception of a new top cover label Innovative engineering has provided this shredder with the following operating and safety features 1 Automatic Operation The unit begins to operate when a light beam is broken as paper is inserted into the shredder throat The motor stops running when the light beam is no longer broken and the paper has had an opportunity to clear the cutting head 2 Overload Warning Whenever the capacity of the shredder is exceeded the unit stops shredding and the Reverse symbol illuminates 3 Thermal Protection The motor is equipped with a thermal protection device which is triggered if the motor temperature reaches a predetermined level The motor will not operate until it cools 4 Bag Full Sensor When the shred bag becomes full the motor automatically turns off and the Bag light symbol illuminates The shredder will not operate until the shredded material is either compressed down or emptied 5 Door Ajar Sensor When the door of the shredder is not fully closed the Door light s
7. 8 5 2 Electrical Operation When the rocker standby off reverse switch S1 is depressed in the I position the green control light will illuminate to indicate the shredder is in the standby mode Power is supplied from the hot side of the circuit to the following components the circuit breaker contactor motor and the control board The neutral line is fed through the contactor and to the control board When the photocells sense paper in the throat area the circuit is completed through the control board allowing the contactor to supply power to the motor When the shredder is in the stand by mode and the door of the shredder is opened the door ajar icon illuminates The control board disables the circuit that provides power to the motor until the door is closed When the bag full flap switch is opened the bag full icon will illuminate The control board then disables the circuit to the motor until the shredder is cleared or emptied When the shredder is severely loaded down the control board turns on the reverse symbol icon and disables the circuit to the motor 5 3 Electrical Components Motor The motor is a single phase 3 5 HP thermally protected gearmotor which is designed for continuous operation Capacitors 30uF 40uF These capacitors assist the motor in starting and running 5 0 TROUBLESHOOTING 5 3 Electrical Components Stand by Off Reverse Switch The Stand by Off Reverse switch
8. d With the positive meter probe on the black stripped emitter wire and the negative meter probe on the emitter wire check for 737 ohms Reverse the meter leads and infinity should be read Receiver Set meter to read 20M ohms Disconnect the receiver from the control board With the positive meter probe on the gray wire and the negative meter probe on the black receiver wire check for 1 47 Mega ohms under normal room light The resistance will increase when blocked Reverse the meter leads and infinity should be read 5 0 TROUBLESHOOTING 5 4 Testing Electrical Components cont Circuit Breaker Continuity should be read across the two terminals when the breaker pin is pushed in and Infinity is read when tripped Forward Contactor Set for 200VAC Check output voltage terminal 2T1 black lead and terminal block point Z gray lead for 213VAC when the sensors are blocked and in the run mode Contactor resistance across A1 amp A2 should read 140 ohms Reverse Contactor Set dvm for 200VAC Check output voltage terminal 4T2 amp 6T3 for 115VAC when the control switch is depressed in the reverse position Contactor resistance across A1 amp A2 should read 140 ohms Control Board Output Voltages Set dvm to read 200 VAC e Pc board output voltage to the forward contactor should read 115VAC across pins 6 amp 7 with the sensors blocked and in the run position e Pc board output voltage to the reverse co
9. he electrical leads that were removed to facilitate reconnecting them Refer to the wiring diagram in Figure 5 7 to resolve any wiring difficulties that may occur E ZA WARNING Always unplug the shredder to avoid possible electrical shock hazard before attempting to perform any repairs 5 0 TROUBLESHOOTING Shredder does not Power cord disconnected Connect power cord operate no Indication of power Stand by Off Reverse switch Test section 5 4 and defective replace if necessary Shredder does not Cabinet door open Close door operate with indication of power present Shred bag full Empty bag Motor thermal cut off Allow motor to cool triggered Door sensor defective Test section 5 4 and replace if necessary Control board defective Test section 5 4 and replace if necessary Defective capacitor Replace capacitor Motor defective Check motor input voltage replace motor if necessary Shredder does not Photo diode defective Test section 5 4 and operate automatic mode replace if necessary Control board defective Shredder runs Defective forward reverse Test section 5 4 and continuously Switch replace if necessary Dust or scratch on photo Clean or replace Sensors Defective PC board Test section 5 4 and replace if necessary Receiver defective Emitter defective Sheet capacity Cutters need lubrication Lubricate cutters diminished Cutters out of time Time lt See Figure 6 8 Dull cutters Replace cu
10. isconnect the shredder from its power source before cleaning The cover and cabinet may be cleaned with a soft cloth moistened with a mild detergent and warm water Do not use chemical cleaners or solvents as these may have a harmful effect Use detergent sparingly to avoid contact with electronic components 7 2 Inspection Whenever the cover has been removed for corrective maintenance visually inspect for defects such as loose screws or nuts damaged wire insulation loose terminals etc Correct any defects before returning the shredder into service 7 3 Lubrication The 5160x should be lubricated whenever a decrease in sheet capacity is noticed Use a lubricant such as E Z 1 oil P N 1961508 which does not attract dust Following the steps below will help the 5160X maintain maximum sheet capacity and efficiency METHOD A 1 With the shredder off spray a steady stream of lubricant into the throat area from side to side 2 Run the shredder in both directions for a few seconds this will help distribute the lubricant throughout the cutters METHOD B 1 Spray S pattern of lubricant across scrap sheets of paper 2 Turn the shredder on shred the lubricated sheets 3 When shredding is complete reverse the shredder direction to help distribute the lubricant throughout the cutters 4 Repeat these three steps until shredder capacity is restored No periodic lubrication of the cutter gears is re
11. ns the machine will not operate when the cabinet door is open The red control symbol d will light 4 Whenever the shred capacity has been exceeded the unit will stop shredding The reverse symbol R e will light Press the rocker switch a into position R and reduce the paper stack and begin shredding again In the case of a severe jam it may be necessary to tear off the paper as close to the Figure 4 1 throat as possible Then alternately rock the control switch between the Forward and Reverse positions until the jam has cleared the cutting head During this operation the thermal overload protector of the motor may be triggered and the motor will appear inoperable Wait a few minutes to allow the motor to cool then clear the jam 5 Waste that does not need to be shredded can be thrown into the waste area A Rocker control Switch B Stand by Control Symbol C Bag full Symbol D Door ajar Symbol E Reverse Symbol 5 0 TROUBLESHOOTING 5 1 Mechanical Operation The shredder uses two rotating cutting shafts which are driven by an electrical motor to shred paper Both the upper and lower cutters are precisely milled with a helix The cutter blades are progressively staggered and give the cutters a spiraling effect The upper and lower cutter blades are meshed with each other and the cutting teeth are timed to engage each other at precisely the right point Cutter timing is explained in Section 6
12. ntactor should read 115VAC across pins 6 amp 8 with the sensors blocked and in the reverse mode e Pc board output voltage to the control switch should read 115 across pins 1 amp 3 and 2 amp 3 when the control switch is in the off position e Pc board output voltage to the emitter and receiver should read 3 14dc across pins 3 amp 4 and 10vdc across pins 1 amp 2 when the emitter and receiver are disconnected e Pc board output voltage to the safety sensors should read 11 82vdc between pins 1 amp 2 of x5 and x6 when both sensors are disconnected 5 0 TROUBLESHOOTING 5 5 General Troubleshooting Malfunction corrections are based on visual observations made by the operator The causes of the malfunctions are isolated by the symptom of the malfunction and noting at which point in the operating cycle the malfunction occurred Malfunctions may be pinpointed to a defective electrical component or mechanical part by referring to the Principles of Operation the troubleshooting guide and the wiring diagram 5 6 Troubleshooting Chart The troubleshooting guide chart that follows is arranged in order of the normal operational sequence When a malfunction occurs read down the SYMPTOM column until you find the appropriate description for your symptom Read the corresponding PROBABLE CAUSE then perform the recommended procedure in the CORRECTIVE ACTION column When replacing electrical components that have push on terminals label t
13. p Gear puller 6 jaws Ve socket w ratchet Vise grips standard size Snap ring pliers Volt ohm multimeter Amprobe Hammer 10 Metric wrenches 8mm 10mm 11 Metric hex keys 12 Adjustable wrench 6 2 Upper Cover Removal Disassembly of the shredder is described in the following steps Referencing Section 8 0 will help you understand the text Disconnect the unit from the receptacle before performing any disassembly procedures 1 With the shredder upside down remove the twelve phillips head screws from the base lip 2 Remove and carefully place the cover to one side 3 Disconnect the wiring harness from the control panel board 4 After noting the wire sequence disconnect the circuit breaker leads and control switch leads 5 Noting wire sequence unscrew the power cord leads from the terminal block with a straight blade jewelers screw driver 6 3 Bottom Cover Removal 1 Complete Section 6 2 Upper Cover Removal 2 Disconnect the ground wire from the side frame 3 Remove the six hex head screws from the bottom cover using a 10mm socket and driver 4 Disconnect the front and rear sensors from the control board 5 Slide the cutter assembly out of the bottom cover 6 4 Motor Removal 1 Complete Section 6 2 Upper Cover Removal 2 Complete Section 6 3 Lower Cover Removal 3 Disconnect leads X4 5 and 6 from the control board 4 Noting the wi
14. quired However when gears are replaced they should be lubricated with a good quality gear lubricant 8 0 PARTS LIST parts in each illustration are keyed with an index number for reference to the respective part number part name and quantity in the parts list The quantities for the 5160X shredder are shown in the respective quantity column When ordering service parts always include the following information Machine Model Number Machine Serial Number Part Number Part Name Quantity Required NOTE The Northbrook Service Parts Department does not stock all hardware To avoid delay standard hardware shown in this parts list should be procured locally whenever possible 5160 5 LIST FIGURE 8 1 9002 293 4000 736 9002 943 2201 205 gt NS E 9002 984 i pe lt lt 2601 550 SN S 120 S i EM S 040 4004 SS 9001 920 550 2601 S 5 205 2201 T 984 9002 178 17 5160 PARTS LIST FIGURE 8 2 G09 J006 60 910 0098 gt Wc Str 0007 LOL 7007 818 7007 910 0096 5160 PARTS LIST 18 FIGURE 8 3 HOOF 40 700 ved 2006 210 7007 097 OOF 210 7007 220 700 785 288 006 480 7007 5160 PARTS LIST FIGURE 8 4 9002 497 9002 oo 4004 173 4004 007 9001
15. ring sequence disconnect the coded wires 1 9 from the control board 5 Removed the control board 6 Unscrew the nylon control board posts 7 Remove the control board insulator 12 6 0 DISASSEMBLY ASSEMBLY ADJUSTMENTS 6 4 Motor Removal cont 8 Remove the four 10mm hex head screws from the gear cover 9 Remove ground strap from RH side frame 10 Remove master link from chain remove chain 11 Remove four 13mm motor bolts 12 Disconnect the motor wiring harness and ground lead 13 Slide the motor towards the inside of chassis 6 5 Gearbox Chassis Removal 1 Complete Section 6 2 Upper Cover Removal 2 Complete Section 6 3 Lower Cover Removal 3 Complete Section 6 4 Motor Removal 4 Remove two 5mm allen head screws and washers from the main cutter gear and upper cutter drive gear 5 Using a gear puller remove the main cutter gear assembly 6 Remove the upper cutter gear Please note the orientation of the cutters key ways for assembly purposes They must be in series for proper timing 6 Remove two deflectors from each side by removing two pan head screws from each side 7 Remove four nuts and two hex head bolts 13mm amp 15mm from the gear box chassis The chassis can now be removed 6 6 Cutter Shaft and Stripper Assembly Removal 1 Complete Section 6 2 Upper Cover Removal 2 Complete Section 6 3 Lower Cover Removal 3 Complete Section 6 4 Motor Removal 4
16. tters Worn bearings Replace bearings 10 5 0 TROUBLESHOOTING 2102 55047 X091S 15 nm 2409 ASH 12 J0j0 mom n hu mer gs PERCHE r Cer 9 o S lta Q J Ol J 2 N a e a Je z LO 9098 ids Esie 2 8 e D 5 O O o suUsuaS H323 5 MOA EEA o 4 Ajajes TEA gous pma Seg 6 0 DISASSEMBLY ASSEMBLY ADJUSTMENTS 6 1 Necessary Tools The following tool list is necessary for disassembly assembly adjustments Phillips screwdriver 1 tip Phillips screwdriver 2 ti
17. ymbol illuminates This is a safety feature that will only allow the shredder to operate when the cabinet door is in the closed position Before using your GBC Shredmaster shredder carefully read the operating instructions in this manual Once you have gained experience and familiarity with its operation you will be better equipped to use the remaining sections of this manual to troubleshoot and repair the shredder 2 0 SPECIFICATIONS Required 115V AC 10 60 Hz Electrical 15 AMP Two Wire Service with Ground Service oy Eee Electrical 115V AC Rating 9 15AMPS Single Phase Motor 3 5 Output HP 962 Watts 9 15A Thermally Protected se el Motor Continuous Duty Duty Cycle bin cuc c Power 1000 05 Watts 17 Sheets Nominal Consumption Line U U UI Dimensions 38 50 High 24 00 Wide 22 00 Deep Pounds 245 a Shredding 26 5ft min 1 sheet 18 5ft min 18 Speed sheets _______ Shred Size 3 16 x 2 3 8 4mm x 60mm Throat 16 _________ Shredder 18 22 sheets of 8 5 x 11 Capacity 20 Bond Paper ee Noise Level Bag Size ___6_______ Noise Level 67 5 No Load 81 0 Full Load E uiia Bag Size 48 H 24 W 18 D pu l Shipping Dimensions LxWxH Head 2834 274 15 Cabinet 2824 262 384 3 0 INSTALLATION PROCEDURES Figure 1 Adcaution Two people are
Download Pdf Manuals
Related Search