Machine Specs

Model: FD 8902CC

Serial #: __________________

Motor

7.5KW (10HP)

Power

220V / 60Hz / 3-Phase

Sheet Capacity

Up to 650 Sheets

Throat Width

Weight

1,984 lbs.

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 Guarantee claims and inquiries cannot be processed if you do not quote the machine number.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.

TABLE OF CONTENTS

TOPIC

PAGE

Cutting Data, Speed, Dimensions, Weight

Motor Specifi cations, Power Requirements

Start-up: Main Switch and Control Panel

Maintenance: Removing Side Covers

Maintenance: Conveyor Belt Maintenance

Maintenance: Lubricating Shredder Mechanisms

Safety Precautions

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.

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.

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.

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
• safe attachment
• specifi ed location
• 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:

The shredder must switch off immediately when you press the Safety Bar and the Emergency Stop 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.

General Overview

Front View with Waste Bin

Left Side View with Electricity Control Box Access Door

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

FD 8902CC

Cutting Style: Shred Size: Sheet Capacity: Speed: Feed Opening: Dimensions: Feed Table Dimensions: Space Requirements: Bin Capacity: Weight:

Cross Cut 5/16” x 1-1/2” - 3” Up to 650 Up to 35 feet per minute 21” 47” W x 81” L x 63” H 47” W x 23.5” D x 49.5” H 79” W x 100.5” L x 118” H 102 gal. 1,984 lbs.

Motor Specifi cations, Power Requirements

Motor Type Rated Power Operating Voltage Phase Frequency Plug/Receptacle

Horizontal Geared 7.5KW (10HP) 220/380V 3-Phase 50/60Hz CS8365 plug included CS8369 receptacle required 25.5A/14.7A 25 RPM/35 RPM

7.5KW 26A 35A

Rated Current Output RPM Number of Poles Total Rated Power Pn Total Rated Current In Total Fuse Protection

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.

Start-up and Operation

Main Switch

Control Panel

LOAD INDICATOR

LED Display Displays load to provide maximum capacity and avoid paper jams.

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.)

REVERSE

Blue Touch Pad Push button to reverse direction of cutting blades.

OFF/ON

Key-Operated Toggle Switch Turn key to right to turn on cutting system.

MODE/FULL/OPEN

INDICATORS LED Displays Lights signify mode (Auto/ Manual/Stop/Reverse) and indicate when bin is full or door is open.

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.

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.

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.

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.

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.

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

NOTE: The maintenance procedures which follow should be performed only by authorized and trained technicians.

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.

• 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.

• 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.

Underside View of Feed Table and Infeed Conveyor

• 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.

• 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.

• 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.

• 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.

• 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.

PARTS LISTS

Front View

Rear View

ITEM

PART #

8902-TOP-01

TOP CASE

DESCRIPTION

QTY

8902-TOP-02

LOADING TABLE

8902-TOP-03

UPPER FRAME (LEFT, RIGHT)

8902-CON-01

CONVEYOR BELT ASSEMBLY

8902-BEL-01

CONVEYOR BELT

8902-BEL-02

CLEAR PLASTIC SAFETY STRIP

8902-TOP-05

FRONT CASE

8902-TOP-06L

LOADING TABLE SUPPORTER, LEFT

8902-TOP-06R

LOADING TABLE SUPPORTER, RIGHT

8902-WST-01

WASTE BIN

8902-TOP-07

CUTTING HEAD ACCESS DOOR

8802-BOL-01

LOADING TABLE SUPPORTER BOLTS

8902-TOP-04

REAR CASE

8902-BOD-01

LOWER FRAME

8902-BOD-02

REAR CASE, LOWER

8902-PCB-13

PCB COVER

8902-PCB-14

PHOTO-EYE SENSOR

8902-OIL-22

EVENFLOW OILER PUMP ASSEMBLY

Left Side

Right Side

ITEM

PART #

DESCRIPTION

8902-BOD-04

UPPER SIDE CASE, LEFT

QTY

8902-BOD-06

LOWER SIDE CASE, LEFT

8902-TOP-07

CUTTING HEAD ACCESS DOOR

8802-PCB-07

MICRO SWITCH, ACCESS DOOR

8902-TOP-02

LOADING TABLE

8902-TOP-06L

LOADING TABLE SUPPORTER, LEFT

8902-TOP-06R

LOADING TABLE SUPPORTER, RIGHT

8902-PCB-02

ELECTRICITY CONTROL BOX DOOR

8902-CAT-01

BODY CASTERS

8902-BOD-03

UPPER SIDE CASE, RIGHT

8902-BOD-05

LOWER SIDE CASE, RIGHT

8902-OIL-22

EVENFLOW OILER PUMP ASSEMBLY

WASTE BIN (FD 8902CC)

8902 CC)

ITEM

PART #

DESCRIPTION

QTY

8902-WST-01

WASTE BIN

8902-WST-02

WASTE BIN DOOR LATCHES

8902-WST-03

WASTE BIN CASTERS

NYLON WASTE BIN BAG

8902-WST-04

WASTE BIN DOOR CASTER

8902-WST-05

WASTE BIN DOOR HANDLE

8902-WST-06

WASTE BIN DOOR

8902-WST-07

WASTE BIN DOOR HINGES

CUTTING HEAD

Right Side

Left Side

ITEM

PART #

DESCRIPTION

QTY

8902-CTB-02

SIDE PLATE, RIGHT

8902-CTB-01

SIDE PLATE, LEFT

8902-CTB-07

LONG SHAFT

8902-GEA-01

GEAR

8902-SPR-03

MOTOR SPROCKET

8902-MOT-01

MOTOR (220V, 60Hz, 10HP)

8902-CCH-01

CUTTING HEAD CHAIN

8902-RUB-01

VIBRATION-PROOF RUBBER (100)

8902-CTB-08

SHORT SHAFT

8902-SPR-01

CONVEYOR SPROCKET

8902-CON-03R

CONVEYOR BELT BRACKET, RIGHT

8902-CON-03L

CONVEYOR BELT BRACKET, LEFT

8902-CCH-02

CONVEYOR CHAIN

8902-SPR-02

CONVEYOR DRIVE SPROCKET

8902-CTB-00

CUTTING HEAD

ELECTRICAL

ITEM

PART #

DESCRIPTION

QTY

8902-MOT-01

MOTOR (22OV, 60Hz, 10HP)

8902-CTB-20

WASTE GUIDE, REAR

8902-CTB-21

MICRO SWITCH, WASTE BIN FULL SENSOR, 15A

8902-PCB-10

POWER PLUG

8902-PCB-15

ELECTRICITY CONTROL BOX COVER

8902-PCB-00

ELECTRICITY CONTROL ASSEMBLY

8902-PCB-05

WIRE TERMINAL PLATE

8902-PCB-09

BREAKER

8902-PCB-06

MAGNETIC CORE

8902-PCB-03

ELECTRICITY CONTROL BOX

8902-PCB-04

EOCR

8902-PCB-01

ELECTRICITY CONTROL BOX BASE

CUTTING HEAD ASSEMBLY

ITEM

PART #

DESCRIPTION

QTY

8902-PCB-23

CONTROL PANEL

8902-PCB-24

EMERGENCY STOP BUTTON

8902-PCB-25

KEY

8902-PCB-12

CONTROL PANEL PCB

8902-PCB-16

BODY CABLE

8902-CTB-09

CUTTER

8902-CTB-10

RING

8902-CTB-11

BEARING (6208ZZ)

8902-CTB-12

CUTTER PRESS WASHER

8902-CTB-13

BEARING WASHER

8902-CTB-14

BEARING NUT

8902-CTB-15

CUTTER NUT

8902-CTB-16

BEARING HOUSING

8902-CTB-17

GUIDE REINFORCEMENT PLATE

8902-CTB-18

UPPER GUIDE

8902-CTB-19

LOWER GUIDE

8902-CON-02

CONVEYOR SHAFT HOLDER

8902-CTB-07

LONG SHAFT

8902-CTB-08

SHORT SHAFT

8902-CTB-03

POST

Underside View, Safety Bar and Micro Switch

Underside View, Feed Table and Conveyor

ITEM

PART #

DESCRIPTION

QTY

8902-PCB-08

MICRO SWITCH, WASTE BIN FULL

8902-CTB-20

WASTE GUIDE, REAR

8902-CTB-06

WASTE GUIDE, LEFT & RIGHT

8902-PCB-20

MICRO SWITCH, SAFETY BAR

8902-PCB-21

MICRO SWITCH HOUSING FOR SAFETY BAR

8902-PCB-22

SAFETY BAR

8902-CTB-04

FRONT WASTE PROOF PLATE

EVENFLOW OILING SYSTEM

Top View with Access Door open

ITEM

PART #

DESCRIPTION

QTY

8902-OIL-20

OIL NOZZLE, 10 PIECE

8902-OIL-21

OIL NOZZLE, 5 PIECE

8902-OIL-22

OIL PUMP

8902-OIL-23

OIL NOZZLE BRACKET

8902-OIL-24

OIL HOSE

8902-OIL-25

PUMP MOUNTING SCREWS

8902-OIL-26

NOZZLE BRACKET MOUNTING SCREWS

OPTIONAL 8900-10 CONVEYOR

ITEM

PART #

DESCRIPTION

QTY

CONVEYOR SIDE, LEFT

COVER

HOPPER

BODY CASE

CHAIN COVER

CONVEYOR SIDE, RIGHT

CHAIN SPROCKET (A)

CHAIN

CHAIN SPROCKET (B)

CASTER

ITEM

PART #

DESCRIPTION

CONVEYOR TENSION BOLT

CONVEYOR POST

WASTE PLATE

WASTE PLATE HANDLE

QTY

ITEM

PART #

DESCRIPTION

QTY

STOPPER

GUIDE, RIGHT

CONVEYOR BELT

GUIDE, LEFT

DOOR HANDLE

DOOR BOLT

DOOR LATCH

LATCH NUT

DOOR HANDLE ASSEMBLY