GBC Shredmaster 5160X User manual

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 symbol 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

Electrical

Service:

115V AC +/ -10%, 60 Hz,

15 AMP, Two Wire Service with Ground

Electrical

Rating:115V AC

9.15AMPS

Single Phase

Motor: 3/5 Output HP @ 962 Watts, 9.15A,

Thermally Protected

Motor

Duty Cycle: Continuous Duty

Power

Consumption: 1000.05 Watts @ 17 Sheets, Nominal

Line

Dimensions: 38.50” High

24.00” Wide

22.00” Deep

Weight: 245 Pounds

Shredding

Speed: 26.5ft/min. @ 1 sheet, 18.5ft/min. @ 18

sheets

Shred Size: 3/16” x 2 3/8” (4mm x 60mm)

Feed Throat

Width: 16”

Shredder

Capacity: 18 -22 sheets of 8.5” x 11”

20# Bond Paper

Noise Level: 67.5 No Load, 81.0 Full Load

Bag Size: 48”H, 24”W, 18”D

Shipping Box Dimensions L x W x H

Head 28¾”, 27¼”, 15”

Cabinet 28¾”,26½”,38¼”

3.0 INSTALLATION PROCEDURES

CAUTION: Two people are

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 1

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

“I”. 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 concerns 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

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 flap

area.

A = Rocker control Switch B = Stand-

by Control Symbol

C = Bag full Symbol D = Door ajar Symbol

E = Reverse Symbol

Figure 4.1

5.O 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 6.8.

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.O TROUBLESHOOTING

5.3 Electrical Components

Stand-by/Off/Reverse Switch -The

Stand-by/Off/Reverse switch, 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

WARNING: 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

board. With the positive meter probe on

the black stripped emitter wire and the

negative meter probe on the gray

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.O 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 dvm 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 & A2 should read 140 ohms.

Reverse Contactor -Set dvm for 200VAC. Check output voltage @ terminal

4T2 & 6T3 for 115VAC when the control switch is depressed in the reverse

position. Contactor resistance across A1 & A2 should read 140 ohms.

Control Board Output Voltages -Set dvm to read 200 VAC.

•Pc board output voltage to the forward contactor should read 115VAC across

pins 6 & 7 with the sensors blocked and in the run position.

•Pc board output voltage to the reverse contactor should read 115VAC across

pins 6 & 8 with the sensors blocked and in the reverse mode.

•Pc board output voltage to the control switch should read 115VAC across pins

1 & 3 and 2 & 3 when the control switch is in the off position.

•Pc board output voltage to the emitter and receiver should read 3.14dc across

pins 3 & 4 and .10vdc across pins 1 & 2 when the emitter and receiver are

disconnected.

•Pc board output voltage to the safety sensors should read 11.82vdc between

pins 1 & 2 of x5 and x6 when both sensors are disconnected.

5.O 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 the 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.

WARNING: Always unplug the shredder to avoid possible electrical

shock hazard before attempting to perform any repairs.

5.0 TROUBLESHOOTING

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

Shredder does not

operate, no Indication of

power

Power cord disconnected.

Stand-by/Off/Reverse switch

defective

Connect power cord

Test (section 5.4) and

replace if necessary

Shredder does not

operate, with indication of

power present

Cabinet door open

Shred bag full

Motor thermal cut off

triggered

Door sensor defective

Control board defective

Defective capacitor

Motor defective

Close door

Empty bag

Allow motor to cool

Test (section 5.4) and

replace if necessary

Test (section 5.4) and

replace if necessary

Replace capacitor

Check motor input voltage

replace motor if necessary

Shredder does not

operate, (automatic mode

only)

Photo diode defective

Control board defective

Test (section 5.4) and

replace if necessary

Shredder runs

continuously Defective forward/reverse

switch

Dust or scratch on photo

sensors

Defective PC board

Receiver defective

Emitter defective

Test (section 5.4) and

replace if necessary

Clean or replace

Test (section 5.4) and

replace if necessary

Sheet capacity

diminished Cutters need lubrication

Cutters out of time

Dull cutters

Worn bearings

Lubricate cutters

Time cutters (See Figure

6.8)

Replace cutters

Replace bearings

5.0 TROUBLESHOOTING

5.7 Wiring Diagram

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