Service and Parts Manual Rexel Shredder 415-425-432 Autoplus

PAPER SHREDDER 415/425/435 AUTOPLUS

SERVICE MANUAL

WITH ILLUSTRATED SPARE PARTS LIST

DEM ISSUE 4 NOVEMBER 05 PAGE 1


PREFACE

This manual provides the instructions for the replacement of all the components that

may become worn or damaged during normal usage of the machine.

Illustrated Parts List - For each model gives full details of the replacement part numbers with supporting diagrams to show the

location of the components.

Service Instructions - Give the recommended servicing procedure with supporting pictorial diagrams for added clarity.

WARNING

1. Check the machine RATING PLATE DETAILS are compatible with the electrical

mains supply.

2. Disconnect the electrical mains supply before removing any covers.

3. After removing the cover on single phase machines DISCHARGE the capacitor by

shorting out its connections.

(BEWARE: PAPER DUST IS A POTENTIAL FIRE HAZARD).

4. The machine MUST have a sound Electrical Earth Connection.

NOTE: The electric motor is protected by an Automatic Thermal Overload Cut-Out.

Product Testing after Servicing or Repair.

IMPORTANT. If any electrical component has been changed, an electrical connection

broken and remade, or any wiring disturbed, the product being repaired or serviced

must be flash tested or PAT tested. This test must be carried before a product is

handed back or returned to the customer or returned to stock. The test must be

appropriate for the machine being repaired. E.g. double insulated of earthed. A

competent person should conduct the test and keep a log of all machines tested, the

serial number of the machine, the details of the test, the test results and the date the

test was carried out.



INDEX

ILLUSTRATED PARTS LIST

SECTION TITLE PAGE Nos ISSUE No

1 CUTTING HEAD 4 – 6 3

2 AUTOFEED UNIT 7 – 8 3

3 HINGED COVER 9 – 10 3

4 CABINET 11 – 12 4

5 ELECTRICS 13 – 15 4

SERVICE INSTRUCTIONS

SECTION TITLE PAGE Nos ISSUE No

1 REMOVAL OF TOP COVER 16 & 17 3

2 REMOVAL OF HINGED COVER 16 & 18 3

3 REMOVAL OF AUTOFEED UNIT 19 3

4 REPLACING DRIVE BELT 19 & 20 3

5 REPLACING FEED DRIVE BELT 19 & 22 3

6 REPLACING FEED BELT 21 & 22 3

7 REPLACING FEED UNIT DRIVE PULLEY 21 & 22 3

8 REPLACING FEED UNIT DRIVEN PULLEY 21 & 22 3

9 REPLACING CUTTING HEAD 23 & 24 3

10 REPLACING GEARBOX 25 & 26 3

11 REPLACING PERSPEX FLAP 27 & 28 3

12 REPLACING POWER ON/OFF SWITCH 27 & 30 3

13 REPLACING MAIN POWER SOCKET 29 & 30 3

14 REPLACING DOOR SAFETY SWITCH 29 & 30 3

15 REPLACING HINGED COVER MICROSWITCH 29 & 31 3

16 REPLACING BIN FULL FLAP MICROSWITCH 32 3

17 REPLACING AUTO START/STOP SENSORS 32 & 33 3

18 REPLACING MOTOR 34 & 35 3

19 REPLACING THE MAIN CONTROL PCB 34 & 36 3

20 REPLACING CONTROL SWITCH PCB 34 & 37 3

21 MAIN CONTROL PCB ADJUSTMENT 38 & 39 3

22 TIMING 1/1 GEARS 38 & 40 3

23 WIRING DIAGRAM 41 3

24 SPECIFICATION SHEET 42 4

AMENDMENT SHEET 43


PAPER SHREDDER 415/425/435 AUTOPLUS SECTION 1

ILLUSTRATED PARTS LIST – CUTTING HEAD

NO PART

NO

DESCRIPTION

415

QTY

425

435

COMMENTS

A48402 415 CUTTING HEAD ASSEMBLY 1 - -

A48401 425 CUTTING HEAD ASSEMBLY - 1 -

A48400 435 CUTTING HEAD ASSEMBLY - - 1

1 A48382 INNERSIDE PLATE ASSEMBLY R/H - - 1

A48384 INNERSIDE PLATE ASSEMBLY R/H 1 1 -

2 A48381 INNERSIDE PLATE ASSEMBLY L/H - - 1

A48383 INNERSIDE PLATE ASSEMBLY L/H 1 1 -

3 45161SP GEARBOX ASSEMBLY 1 1 1

4 45040 DEJAM PLATE - - 1

45541 DEJAM PLATE 1 1 -

5 TRU 84 GEAR CASING CLIP 1 1 1

6 45017 1:1 GEAR - - 2

45542 1:1 GEAR 2 2 -

7 45006 GEARBOX COVER - - 1

45209 GEARBOX COVER 1 1 -

8 45159 DRIVE SHAFT ADAPTOR 1 1 1

9 45160 DRIVE SHAFT ADAPTOR 1 1 1

10 44828BI STRIPPER LOCATION PLATE - - 1

45208BI STRIPPER LOCATION PLATE 1 1 -

11 BR23 BALL BEARING WITH SNAP RING 2 2 2

12 44841 GEARBOX COVER ASSEMBLY - - 1 ITEM Nos 7,10 & 11 ONLY

45217 GEARBOX COVER ASSEMBLY 1 1 - ITEM Nos 7,10 & 11 ONLY

13 SL22-80 DRIVE BELT 450-5M-15 1 1 1 MOTOR TO GEARBOX

14 44553 TIE BAR - - 1

15 44519 STRIPPER TIE BAR 1 1 2

44694 STRIPPER TIE BAR 1 1 -

16 D48303 CUTTER DRIVEN SHAFT - - 1

D48407 CUTTER DRIVEN SHAFT - 1 -

D48366 CUTTER DRIVEN SHAFT 1 - -

17 44893 CUTTER DRIVE SHAFT - - 1

D48406 CUTTER DRIVE SHAFT - 1 -

44510 CUTTER DRIVE SHAFT 1 - -

18 D48306 PAPER GUIDE ASSEMBLY L/H - - 1

D48307 PAPER GUIDE ASSEMBLY R/H - - 1

D48369 PAPER GUIDE 2 2 -

19 14737 CUTTER - - 155

14738 CUTTER - - 155

D48405 CUTTER - 148 -

D48388 CUTTER 148 - -

20 44815 STRIPPER - - 310

D48377 STRIPPER 148 148 -

21 9115B SPACER CUTTER - - 310

45056 SPACER CUTTER 148 148 -

22 44808 SHAFT COLLAR - - 4

45057 SHAFT COLLAR 4 4 -




23 9076BI LOCKNUT - - 4

NM28 LOCKNUT KM6 2 2 -

TAB4 TAB WASHER MB6 2 2 - FOR NM28

TRU70 CIRCLIP 2 2 -

24 KEY 27 KEY 30 x 5 x 5mm 1 1 1

25 KEY 28 KEY 16 x 5 x 5mm 1 1 1

26 D48302 INFEED EXTENSION LOWER - - 1

27 PEG 65 PEG 4mm Dia x 24mm 1 1 1 FOR 28 DRIVE PULLEY

28 D48304 DRIVE PULLEY AUTO FEED 1 1 1

29 45539BI SPACER 2 2 2

30 PLN5L LARGE PLAIN WASHER 2 2 2

31 SCM 59 HEX HEAD SCREW M8 x 30mm 2 2 2

32 NM22 NYLOC NUT M8 2 2 2

33 SHK4 SHAKEPROOF WASHER M6 4 4 4

34 SCM15 HEX HEAD SCREW M6 x 12mm 4 4 4



37 PLN29 PLAIN WASHER M5 4 4 4

1000757 GUARD BRACKET 1 1 1 FIT TO ITEM 1 WITH

ITEM 34.



ILLUSTRATED PARTS LIST – AUTOFEED UNIT

NO PART

NO

DESCRIPTION

415

QTY

425

435

COMMENTS

1 A48376 INNERSIDE PLATE ASSEMBLY L/H 1 1 1

A48385 INNERSIDE PLATE ASSEMBLY R/H 1 1 1

2 D48324 FRONT SUPPORT PLATE 1 1 1

3 D48325 REAR SUPPORT PLATE 1 1 1

4 D48323 BLADE 1 1 1

5 D48308 BIN FULL FLAP - 1 1

D48408 BIN FULL FLAP 1 - -

6 D48329 FEED ROLLER (SPRUNG) 1 1 1

7 D48365 FEED ROLLER (DRIVEN) 1 1 1

8 D48313 INNER TIE ROD 3 3 3

9 SL22-85 GRABBER FEED BELT 3 3 3

10 D48345 DRIVEN PULLEY 1 1 1

BR26 BEARING ASSY 1 1 1 PRESS INTO

PULLEY D48345

SL22-86 DRIVE BELT 1 1 1

11 AA1011A PLASTIC BEARING 2 2 2

12 A48349 BLADE ADJUSTMENT BRKT ASSY

R/H

1 1 1

13 SCM137 FLANGED HEAD SCREW M6 x 25mm 2 2 2

14 A48350 BLADE ADJUSTMENT BRKT ASSY

L/H

1 1 1

15 AA1012 COMPRESSION SPRING 2 2 2

16 D48360 EXTENSION SPRING 2 2 2

17 TRU95 ½” CIRCLIP 2 2 2

18 SCM15 HEX HEAD SCREW M6 x 12mm 6 6 6 FOR TIE RODS 8

19 SHK4 SHAKEPROOF WASHER M6 6 6 6 FOR TIE RODS 8


21 NM8 FULL NUT M5 4 4 4



24 NM3 FULL NUT M4 4 4 4


26 40088 COMPRESSION SPRING 2 2 2

27 D48344 HINGE PIN L/H 1 1 1

28 D48343 HINGE PIN R/H 1 1 1 To S/N A917256

28 D48344 HINGE PIN R/H 1 1 1 From S/N A917256

29 PLN27 PLAIN WASHER 8mm ID x 38mm OD 2 2 2



ILLUSTRATED PARTS LIST – AUTOFEED UNIT



ILLUSTRATED PARTS LIST – HINGED COVER

NO PART

NO

DESCRIPTION

415

QTY

425

435

COMMENTS

1 A48410 HINGED COVER S/W ASSEMBLY - - 1

A48409 HINGED COVER S/W ASSEMBLY 1 1 -

2 A48335 PRESSURE PLATE ASSEMBLY 1 1 1

3 D48346 TRUNNION 2 2 2

4 D48327 PIVOT BAR 1 1 1

5 D48326 SPRING RETAINING BAR 2 2 2

6 D48361 COMPRESSION SPRING 2 2 2

7 PEG82 ROLL PIN MBK 2 2 2

8 A48375 FEED CHUTE FLAP ASSEMBLY 1 1 1

9 D48373 HINGE BLOCK 2 2 2

10 PLN4L PLAIN WASHER M6 4 4 4


12 PLN29 PLAIN WASHER M5 2 2 2


14 SCM 15 HEX HEAD SCREW M6 x 12mm 2 2 2


16 45627 DOOR HANDLE 1 1 1

17 TRU85 PUSH ON FIX 5mm 2 2 2

18 D000366 WARNING DECAL 1 1 -

D000367 WARNING DECAL - - 1

TRU31 PUSH ON FIX 2 2 2 PIVOT BAR 4 TO

RETAINING BAR 5



ILLUSTRATED PARTS LIST – HINGED COVER



ILLUSTRATED PARTS LIST – CABINET

NO PART

NO

DESCRIPTION

415

QTY

425

435

COMMENTS

1 A48403 TOP COVER ASSEMBLY 1 1 1 To S/N A917256

1000869 TOP COVER ASSEMBLY 1 1 1 From S/N A917256

2 D48309 MACHINE BASE 1 1 1

3 A48357 CABINET MAIN PANEL ASSEMBLY 1 1 1

4 A48355 CABINET DOOR SPOT WELD ASSY 1 1 1

5 D000324 SWITCH/LED DECAL 1 1 1 To S/N A917256

1000729 AUTOPLUS SWITCH DECAL 1 1 1 From S/N A917256

6 D54229 BIN PANEL 1 1 1

D53820C HANDLE No Longer Used

7 40095 WASTE SACK 1 1 1

8 D000323 435 AUTOPLUS MODEL DECAL - - 1

D000322 425 AUTOPLUS MODEL DECAL - 1 -

D000321 415 AUTOPLUS MODEL DECAL 1 - -

9 SL18-87 CAM LOCK WITH KEY 1 1 1

10 45627 DOOR HANDLE 1 1 1

11 TRU85 PUSH ON FIX 5mm 2 2 2

12 SL18-259 50mm TWIN WHEEL CASTOR 2 2 2

13 SHK6 SHAKEPROOF WASHER 10mm 2 2 2

14 PLN28 PLAIN WASHER 10mm 2 2 2

15 SCM142 HEX HEAD BOLT M8 x 50mm 2 2 2

16 SL18-303 NYLON WHEEL 50mm 2 2 2

17 NM22 NUT NYLOC M8 2 2 2

18 SL18-245 NYLON SPACER 1 1 1 BOTTOM DOOR

HINGE

19 45610BI HINGE SUPPORT PLATE 1 1 1

20 45967BI BOTTOM DOOR HINGE BRACKET 1 1 1

21 SHK2 SHAKEPROOF WASHER 3BA (4mm) 2 2 2


23 SL18-200 DOOR SPACER 1 1 1 TOP DOOR HINGE

24 SL23-12 DOOR CATCH MAGNET 1 1 1

25 RP435 RATING PLATE DECAL - - 1

RP425 RATING PLATE DECAL - 1 -

RP415 RATING PLATE DECAL 1 - -

26 PLN29 PLAIN WASHER M5 6 6 6 TOP COVER TO

CABINET

27 SHK10 SHAKEPROOF WASHER M5 6 6 6 AS ABOVE

28 SCM20 HEX HEAD SCREW M5 x 16mm 6 6 6 AS ABOVE

29 SCM135 C’SUNK SCREW M5 x 16mm 2 2 2 TOP COVER

FRONT TO

CABINET

30 PLN29 PLAIN WASHER M5 3 3 3 MACHINE BASE

TO CABINET

31 SHK10 SHAKEPROOF WASHER M5 3 3 3 AS ABOVE

32 SCM40 HEX HEAD SCREW M5 x 12mm 3 3 3 AS ABOVE




PLN29 PLAIN WASHER M5 4 4 4 AUTOFEED UNIT

TO CABINET

SHK10 SHAKEPROOF WASHER M5 4 4 4 AS ABOVE

SCM20 HEX HEAD SCREW M5 x 16mm 4 4 4 AS ABOVE

33 25238 SAFETY SWITCH BRACKET 1 1 1 From S/N A917256

1000755 SWITCH BRACKET 1 1 1 From S/N A917256

SCM20 4 4 4 From S/N A917256

NM10 4 4 4 From S/N A917256

PLN3L 8 8 8 From S/N A917256

25246 LINK AND BOSS ASSEMBLY 1 1 1 From S/N A917256

SCM80 1 1 1 From S/N A917256

SL18-20 1 1 1 From S/N A917256

NM10 1 1 1 From S/N A917256



ILLUSTRATED PARTS LIST – ELECTRICS SECTION 5

NO PART

NO

DESCRIPTION

415

QTY

425

435

COMMENTS

1 SL20-300 MOTOR 550W 2 POLE 220-240V 1 1 1 To S/N A917256

SL20-323 MOTOR 550W 2 POLE 220-240V

(3 WIRE)

1 1 1 From S/N A917256

SL20-218 MOTOR 550W 2 POLE 115V 1 1 1 TO SUIT SUPPLY

2 SL6-59 CAPACITOR 25 MFD 440V 1 1 1 220-240 V SUPPLY

To S/N A917256

SL6-60 CAPACITOR 30 MFD Metal Case 1 1 1 220-240 V SUPPLY

From S/N A917256

SL6-30 CAPACITOR 50 MFD 1 1 1 115V SUPPLY

3 SL17-189 MAIN PCB 1 1 1 220-240 V SUPPLY

To S/N A917256

SL17-322 MAIN PCB 1 1 1 220-240 V SUPPLY

From S/N A917256

SL17-190 MAIN PCB 1 1 1 115V SUPPLY

4 SL17-218 SWITCH PANEL PCB 1 1 1 To S/N A917256

SL17-319 SWITCH PANEL PCB 1 1 1 From S/N A917256

5 45605 FORWARD SWITCH PAD 1 1 1 To S/N A917256

6 45606 REVERSE SWITCH PAD 1 1 1 To S/N A917256

7 45604 STOP SWITCH PAD 1 1 1 To S/N A917256

8 44753 MOTOR PULLEY 1 1 1

9 SCM27 SOCKET SET SCREW M5 x 10mm 1 1 1 MOTOR PULLEY

10 SL4-88 CORD SET UK 1 1 1 220-240 V SUPPLY

SL4-90 CORD SET EURO 1 1 1 220-240 V SUPPLY

11 SL12-48 APPLIANCE INLET SOCKET 1 1 1 220-240 V SUPPLY

To S/N A917256

SL12-53 APPLIANCE INLET SOCKET 220-240 V SUPPLY

From S/N A917256

12 SL8-146 ON/OFF ROCKER SWITCH 1 1 1 To S/N A917256

13 SL17-170 PCB SUPPORT PILLAR 4 4 4 To S/N A917256

SL17-171 HEX PCB SPACER 1 1 1 To S/N A917256

SL17-320 PCB SUPPORT PILLAR 1 1 1 From S/N A917256

SL17-321 PCB SUPPORT PILLAR 3 3 3 From S/N A917256

14 SL8-147 MICROSWITCH POSITIVE BREAK 1 1 1 DOOR To S/N

A917256

SL8-72 DOOR SAFETY SWITCH 1 1 1 From S/N A917256

15 SL8-157 MICROSWITCH HINGED COVER 1 1 1 To S/N A917256

SL8-178 MICROSWITCH HINGED COVER 1 1 1 From S/N A917256

16 SL8-107 MICROSWITCH 1 1 1 BIN FULL FLAP

17 45696 BIN FULL LEAD ASSY 1 1 1 To S/N A917256

18 45695 DOOR SWITCH LEAD ASSY 1 1 1 To S/N A917256

19 SL17-165 AUTO START SENSORS No Longer Fitted

20 SL17-231 AUTO STOP SENSORS 1 1 1

21 D45752 SWITCH MOUNTING PLATE 1 1 1 To S/N A917256

22 45753 SWITCH CAM 1 1 1 To S/N A917256

23 SL17-188 CABLE CLIP 4/2 4/2 4/2 To/From S/N

A917256

24 A44849 MOTOR BRACKET 1 1 1




25 SCR686B BRASS SCREW 2BA x 19mm 1 1 1

26 NUT42B BRASS NUT 2BA 2 2 2

27 SL13-56 RING TERMINATION 2BA 2 2 2

28 PLN3B PLAIN WASHER BRASS 2 2 2

29 SHK3 SHAKEPROOF WASHER 2BA 3 3 3 EARTH STUD

SHK10 SHAKEPROOF WASHER 2BA 6 6 6 MOTOR

SHK10 SHAKEPROOF WASHER 2BA 2 2 2 MOTOR BRACKET

30 SCM20 HEX HEAD SCREW M5 x 16mm 1 1 1 SWITCH

MOUNTING PLATE

To S/N A917256

31 PLN29 PLAIN WASHER M5 1 1 1 AS ABOVE To S/N

A917256

32 SCR496 SCREW POZI PAN No6 x 5/16” 4 4 4 AUTO START

SENSORS

33 NM8 NUT M5 1 1 1 SW MOUNT PLATE

To S/N A917256

34 SCM30 POZI PAN HEAD SCREW 7 7 7 USE LOCTITE 243

35 SCM40 HEX HEAD SCREW M5 x 12mm 6 6 6 MOTOR

SCM40 HEX HEAD SCREW M5 x 12mm 2 2 2 MOTOR BRACKET

36 SCM78 POZI PAN SCREW M3 x 16mm 4 4 4 MICRO SWITCHES

SCM78 POZI PAN SCREW M3 x 16mm 2 2 2 STOP SENSOR

37 SHK12 SHAKEPROOF WASHER M3 4 4 4 MICRO SWITCHES

SHK12 SHAKEPROOF WASHER M3 2 2 2 STOP SENSOR

38 NM7 NUT M3 4 4 4 MICRO SWITCHES

NM7 NUT M3 2 2 2 STOP SENSOR

39 SHK11 SHAKEPROOF WASHER M8 1 1 1 CAPACITOR

40 NM11 THIN NUT M8 1 1 1 CAPACITOR

41 D48354 DUST COVER 1 1 1

1000758 SWITCH SUPPORT BRACKET 1 1 1 From S/N A917256

RTS19 RIVETS FOR SUPPORT BRACKET 2 2 2 From S/N A917256

42 SL17-192 KLAMBUSH KB CABLE SOCKET 1 1 1 115 VOLT

43 A48380 POWER SOCKET BRACKET ASSEMBLY 1 1 1 220/240 VOLT

To S/N A917256

1000868 INLET BRACKET ASSEMBLY 1 1 1 220/240 VOLT

From S/N A917256

A48387 POWER SOCKET BRACKET ASSEMBLY 1 1 1 115 VOLT

PLN29 PLAIN WASHER M5 2 2 2 POWER SOCKET

BRACKET TOBASE

SHK10 SHAKEPROOF WASHER 2BA 2 2 2 AS ABOVE

SCM40 HEX HEAD SCREW M5 x 12mm 2 2 2 AS ABOVE

Sl18-374 FERRITE 1 1 1 From S/N A917256

30 SCM20 HEX HEAD SCREW M5 x 16mm 1 1 1 SW MOUNT PLATE

To S/N A917256

31 PLN29 PLAIN WASHER M5 1 1 1 AS ABOVE To S/N

A917256

32 SCR496 SCREW POZI PAN No6 x 5/16” 4 4 4 AUTO START

SENSORS

33 NM8 NUT M5 1 1 1 SW MOUNT PLATE

To S/N A917256

34 SCM30 POZI PAN HEAD SCREW 7 7 7 USE LOCTITE 243



SERVICE INSTRUCTIONS SECTION 1-2

SECTION 1

REMOVAL OF TOP COVER (FIG 1)

1. To gain access to both cutting head and autofeed unit, first remove all eight

cover screws located inside the cabinet.

2. Loosen power socket location screws.

3. Raise hinged cover to its open position.

4. Lift top cover from the front of the machine and disconnect switch ribbon

cable from the main PCB and the top sensor lead from the switch pad, slide

rearwards and remove.

5. To refit top cover reverse above operations.

SECTION 2

REMOVAL OF HINGED COVER (FIG 2)

1. Remove top cover (see section 1).

2. Raise hinged cover to open position and remove the pressure plate.

3. Disconnect Auto stop and start sensor leads, remove from cable ties and

reposition leads clear from machine.

4. Hold in its raised position securely and remove fixing screw from hinge pins.

5. Whilst springs are free from compression, lever hinged cover over towards

back of machine and remove complete with trunnions and springs.

6. To refit hinged cover, locate trunnions with springs into pivot bar, angle cover

and lever to fit securely and reverse above operations.

7. Re-adjust hinged cover microswitch.




FIG 2.




SECTION 3

REMOVAL OF AUTOFEED UNIT

1. Remove top cover (see section 1).

2. Remove hinged cover (see section 2).

3. Disconnect bin full flap sensor switch and hinged cover sensor switch.

4. Remove all four location screws from base plate.

5. Remove feed drive belt (see section 5).

6. Remove complete autofeed unit.

7. To replace, reverse above operations and locate feed drive belt before securely fixing sideframes to machine base.

SECTION 4 REPLACING DRIVE BELT (FIG 3).

1. Remove the top cover (see section 1).

2. The gearbox pulley and motor drive are on fixed centres. To remove belt, slacken

socket set screws securing motor pulley before “winding” belt off gearbox pulley.

3. To replace belt, position motor pulley half way onto the motor shaft. Fit belt and

“wind” onto gearbox pulley.

4. Align and secure motor pulley with gearbox pulley.

5. Refit cover and test.

SECTION 5

REPLACING FEED DRIVE BELT (FIG 4).

1. Remove the top cover (section 1).

2. Raise hinge cover to open position.

3. Slide belt away and off from drive pulley.

4. Remove drive belt from driven pulley.

5. To replace drive belt reverse above operations.




FIG 3




SECTION 6

REPLACEMENT OF FEED BELT (FIG 4)




4. Remove autofeed unit complete (see section 3).

5. Disconnect extension spring right hand side.

6. Remove compression spring right hand side.

7. Remove all three screws from tie rods right hand side.

8. Remove right hand side frame.

9. Disassemble support plates and feed belts leaving shafts in position.

10. To replace belts reverse above operations.

SECTION 7

REPLACEMENT OF FEED UNIT DRIVE PULLEY (FIG 4)


2. Remove pulley pin.

3. Slide off and remove pulley along with belt.

4. Replace new pulley.

5. Insert pulley pin.

6. Replace drive belt.

7. Replace top cover and test.

SECTION 8

REPLACEMENT OF FEED UNIT DRIVEN PULLEY (FIG 4)


2. Position hinged cover in raised position.

3. Remove feed roller shaft circlip.

4. Remove pulley along with belt.

5. Position replacement pulley and reassemble, reverse as above.



SERVICE INSTRUCTIONS SECTION 9

SECTION 9

REPLACEMENT OF CUTTING HEAD (FIG 5)





5. Remove screws, securing side frame to machine base plate and motor support

brackets.

6. Disconnect leads from motor, door and bin full switches, capacitor and manual

drive microswitch.

7. Slide and tilt cutting head unit towards you and remove.

8. Remove motor, sensors, capacitor and PCB mounting plate.

9. Support head unit on gearbox sideframe (see fig 3). Remove circlip from drive

shaft and remove large manual drive gear from shaft, ensuring key is retained.

10. Remove screws retaining left sideframe to tie bar and ease off sideframe,

retaining bearings and plate.

11. Remove paper guide from shafts.

12. Note that the cutters are to be built with cutting edges in line, ensure plain

edged cutters and knurled cutters are on separate shafts.

13. Replace components where necessary and reassemble in reverse sequence.




Fig 5




SECTION 10

REPLACEMENT OF GEARBOX (FIG 6)





5. Remove the cutting head (section 8).

6. Remove screws securing sideframe to tie bar and PCB support plate.

7. Remove screw securing de-jam and separate gearbox from cover.

NOTE: DO NOT DISTURB 1/1 GEARS if removed, retiming will be required (see adjustment section).

8. The drive pulley is a combined part of the gearbox and is supplied as an assembled

replacement (see fig 4).

9. NOTE: EXAMINE SHAFT BEARINGS FOR WEAR AND REPLACE IF NECESSARY.

10. Should a gear dislodge from replacement box reassemble as fig 4 indicates, position centre

dowel gear into drive pulley, locate centre dowel and engage assembled 1st stage planet gear

carrier with centre dowel gear. At this stage pack with IM2 grease and engage assembled 2nd

stage planet gear carrier with 1st stage drive gear. Support 2

nd stage gear carrier and rotate

drive pulley to seat gears.

11. Align de-jam plate with gear casing and secure gearbox with circlip to sideframe.

12. Offer sideframe assembly to gearbox cover and rotate drive pulley to locate 1/1 key.

13. Locate de-jam plate with sideframe holes and secure to gearbox cover.

14. Secure tie bar and PCB support plate.

15. Return cutting head unit to shredder and secure.

16. Refit autofeed unit, feed drive belt, hinged cover and top cover in reverse sequence to

dismantling.

17. Connect all wiring as (WD295) wiring diagram including switch ribbon cable, secure cover

and test.




SECTION 11

REPLACEMENT OF PERSPEX FLAP (FIG 7)



3. Unscrew and remove one hinge block nut.

4. Remove hinge block and Perspex flap.

5. Replace Perspex flap and reverse above operations.

SECTION 12 (To Serial Number A917256)

REPLACEMENT OF POWER ON/OFF SWITCH


2. Locate switch and securing clips, compress clips on switch body to release and

push switch out of power socket bracket.

3. Disconnect leads and reconnect to replacement switch (see wiring diagram).

4. Push replacement switch into slot in bracket ensuring the “o” marking is

uppermost.

5. Secure cover and test.




SECTION 13

REPLACEMENT OF MAIN POWER SOCKET (FIG 8).


2. Locate socket and securing clips, compress clips on socket body to release and push socket

out of bracket.

3. Disconnect leads and reconnect to replacement socket (see wiring diagram).

4. Push replacement into bracket ensuring that from behind machine that the column containing

two pins is to the left and represents a letter “D” shape.

5. Secure cover and test.


REPLACEMENT OF DOOR SAFETY SWITCH (FIG 9)


2. Disconnect leads from microswitch.

3. Prise apart retaining clips and remove switch.

4. Reconnect leads to replacement switch and seat on to locating pins and secure between

retaining lips.

5. Check that the cam activates the switch when the door is opened, if not, slacken adjustment

screw and rotate with mounting plate as required and secure in position.

6. Secure cover and test machine.


REPLACEMENT OF HINGED COVER SAFETY MICROSWITCH (FIG 10).



3. Disconnect wires and remove securing screws.

4. Position replacement microswitch.

5. Re-connect leads.

6. Re-assemble hinged cover.

7. Set microswitch to operate correctly by adjustment of hinge pin.

8. Using a spare switch pad test operations.

9. Secure top cover and test again.




SECTION 16

REPLACEMENT OF BIN FULL MICROSWITCH


2. Reach under autofeed unit to disconnect leads.

3. Remove both screws to remove microswitch.

4. Position replacement microswitch and secure.

5. Connect leads.

6. Replace top cover.

SECTION 17

REPLACEMENT OF AUTO STOP AND START SENSORS (FIG 11)

N.B. SUSPECT SENSORS SHOULD FIRST BE CLEANED OF PAPER DUST AND INK

BEFORE TESTING IN THE FOLLOWING MANNER:-


2. The auto sensors are fixed centrally to the infeed chute.

3. Connect spare switch pad ribbon cable and switch on power.

WARNING – MACHINE IS NOW “LIVE”.

4. Set test meter to DC and measure voltage as indicated in Fig 11.

Note: on PCB test point is provided adjacent to the sensors loom shown. A special lead

will be required (contact Technical services for availability).

5. With clean sensors, unobstructed, the maximum voltage should be 0.5V.

6. The sensors should now be obstructed with paper and the voltage again measured.

WARNING – THE MACHINE WILL NOW OPERATE.

This voltage should be a minimum of 6.0V.

7. Should the meter reading be outside the above voltages then the sensors should be replaced.

8. Disconnect meter and power to machine; remove ribbon cable and leads from PCB.

9. Remove hinged cover on the feed chute.

10. Remove the screws securing the sensor housing on the feed chute and remove.

11. Fit replacement sensors to feed chute and secure.

12. Re-connect sensor leads and secure with cable ties.

13. Reinstate hinged cover and top cover and test.




SECTION 18

REPLACEMENT OF MOTOR (FIG 12)


2. Remove drive belt and motor pulley.

3. Unscrew and remove motor dust cover.

4. Disconnect motor leads.

5. Remove motor fan.

6. Remove the screws securing the motor mounting plate and remove plate.

7. Remove screws securing motor to sideframe and remove motor.

8. Reassemble in reverse sequence and test the machine.

NOTE:- When refitting rear motor bracket ensure position is as shown in fig 12.


REPLACEMENT OF MAIN PCB UNIT (FIG 13)


2. Access board and measure the resistance setting. This information will serve as a base setting

from replacement of PCB.

3. Remove bin-full and door sensor leads from PCB.

4. Remove all motor and auto-sensor leads.

5. Compress the upper retaining catches on the PCB support and lift board clear.

6. Fit replacement board onto supports and press down to secure.

7. Reconnect all leads as wiring diagram and set sensitivity screw (see section 21). Seal screw

after setting.

SECTION 20

REPLACEMENT OF CONTROL SWITCH PCB (FIG 14)


2. Turn cover over to access PCB.

3. Remove the screws securing the PCB. NOTE: These also secure the switch pads.

4. Fit replacement PCB ensuring switch pads are seated correctly and that the warning LEDs

align with the cover recesses. Use Loctite 243 on the threads of the securing screws.

5. Reconnect ribbon cable. Reinstate cover and test.





MAIN CONTROL ADJUSTMENT (SHEET CAPACITY) SETTING UP (FIG 15)

NOTE: MACHINE MUST BE DISCONNECTED FROM POWER


2. Locate sensitivity setting screw on the main PCB and connect meter to the two pin plug, via

special lead (contact technical services for availability).

3. Set meter to OHM range and with a suitable screwdriver turn the setting screw clockwise to

increase resistance (less sheets) and anti-clockwise to decrease resistance (more sheets).

4. The following settings are an average resistance figure to start adjustment:

415/425 models - 165K 435 model - 300K

5. Check voltage supply is correct before testing machine for maximum number of sheets (see

specification in section 23) and adjust if necessary.

6. Seal setting screw and reinstate top cover and test.

SECTION 22

TIMING 1/1 GEARS (FIG 16)

To obtain an acceptable uniform chip the cutters may require timing. This is achieved when re-meshing

any one of three adjacent teeth on one of the 1/1 gears. Run machine to establish state of cut, if chip is

not clean and to size proceed as follows:-





5. Remove cutting head (see section 8).

6. Disconnect all necessary leads and break cable ties.

7. Remove screws securing gearbox sideframe to tie bar and PCB support plate.

8. Remove screws securing de-jam plate, sideframe and gearbox cover and separate gearbox

from cover.

9. Note position of 1/1 gears and mark one tooth of each gear where they mesh.

10. Slide off 1/1 gear and rotate clockwise by one tooth. Re-engage gear and re-assemble cutting

head and return to cabinet to test for cut.

11. Should chip not improve then repeat steps 2-10 but rotate gear by two teeth ant-clockwise.

12. Reassemble in reverse sequence and check cut with final test.



WIRING DIAGRAM 220/240V WD295 SECTION 23 To Serial Number A917256



WIRING DIAGRAM 220/240V WD450 SECTION 23 From Serial Number A917256



SPECIFICATION SECTION 24

415 425 435

POWER SUPPLY 220/240V 50Hz 220/240V 50Hz 220/240V 50Hz

115V 60Hz 115V 60Hz 115V 60Hz

DIMENSIONS 990 X 513 X 628 990 X 513 X 628 990 X 513 X 628

(H X W X D)

MOTOR POWER 550W 550W 550W

ENTRY WIDTH 224mm 224mm 224mm

(AUTOFEED MANUAL)

SHRED SIZE 2 X 30mm 2 X 15mm 0.8 X 11mm

FEED RATE (M/MIN)

AUTOFEED 8.25 8.25 8.25

MANUAL 9.0 9.0 9.0

SHEET CAPACITY

(MAX A4 SIZE)

AUTOFEED 500 SHEETS 500 SHEETS 500 SHEETS

MANUAL 10 SHEETS 8 SHEETS 7 SHEETS

SAFETY FUNCTIONS ALL MODELS AUTOMATIC STOP WHEN : JAM OCCURS

DOOR OPENS

BINFULL

AUTOFEED UNIT LID OPEN



AMENDMENT RECORD SHEET

ISSUE

NO

DECRIPTION SERIAL NO CARO NO

1 Original - -

3 Updated Manual June 2005

4 PCB Change, Electrical Changes 415 A917087

425 A917256

435 A916806


Service and Parts Manual Rexel Shredder 415-425-432 Autoplus

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Transcript of Service and Parts Manual Rexel Shredder 415-425-432 Autoplus