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MODEL W1839/W1840
6"/8" VARIABLE-SPEED GRINDER OWNER'S MANUAL
(FOR MODELS MANUFACTURED SINCE 3/16)
Phone: (360) 734-3482 • Online Technical Support: [email protected]
COPYRIGHT © MAY, 2016 BY WOODSTOCK INTERNATIONAL, INC. REVISED MAY, 2018 (HE)
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF WOODSTOCK INTERNATIONAL, INC.
#18150JH Printed in China
This manual provides critical safety instructions on the proper setup, operation, maintenance, and service of this machine/tool. Save this document, refer to it often, and use it to instruct other operators. Failure to read, understand and follow the instructions in this manual may result in fire or serious personal injury—including amputation, electrocution, or death.
The owner of this machine/tool is solely responsible for its safe use. This responsibility includes but is not limited to proper installation in a safe environment, personnel training and usage authorization, proper inspection and maintenance, manual availability and compre hension, application of safety devices, cutting/sanding/grinding tool integrity, and the usage of personal protective equipment.
The manufacturer will not be held liable for injury or property damage from negligence, improper training, machine modifications or misuse.
Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are: • Lead from lead-based paints.
• Crystalline silica from bricks, cement and other masonry products.
• Arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: Work in a well ventilated area, and work with approved safety equip ment, such as those dust masks that are specially designed to filter out microscopic particles.
INTRODUCTION......................................2
W1839 Machine Specifications ................. 3
W1840 Machine Specifications ................. 5
Components & Controls ......................... 7
SAFETY................................................8
Standard Machinery Safety Instructions ...... 8
Additional Safety for Benchtop Grinders ... 10
ELECTRICAL........................................ 11
Circuit Requirements .......................... 11
Grounding Requirements ...................... 12 Extension Cords ................................ 12
SETUP............................................... 13
Inventory ........................................ 14
Machine Placement ............................ 15 Bench Mounting................................. 15
Assembly ......................................... 16
Test Run .......................................... 18
OPERATIONS....................................... 19
Operation Overview ........................... 19
Wheel Inspection ............................... 21
Wheel Care ...................................... 22
Wheel Dressing ................................. 23
Wheel Removal & Installation ................ 24
Contents
ACCESSORIES....................................... 25
Grinder Accessories ............................ 25
MAINTENANCE..................................... 26
SERVICE............................................. 27
Troubleshooting ................................. 27
Electrical Safety Instructions ................. 29
Wiring Diagram ................................. 30
PARTS............................................... 31
System Breakdown ............................. 31
System Parts List ............................... 32
Labels & Cosmetics ............................ 33
WARRANTY......................................... 36
USE THE QUICK GUIDE PAGE LABELS TO SEARCH OUT INFORMATION FAST!
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
INTRODUCTION
Contact.Info
We are committed to customer satisfaction. If you have any questions or need help, use the information below to contact us.
Manual.Accuracy
We are proud to provide a high-quality owner’s manual with your new machine!
IMPORTANT:.Before.contacting,.please.get.the.
original.purchase.receipt,.serial.number,.and.
manufacture.date.of.your.machine..This.infor mation. is. required. for. all. Technical. Support.
calls.and.it.will.help.us.help.you.faster..
We made every effort to be exact with the instructions, specifications, drawings, and pho tographs contained inside. Sometimes we make mistakes, but our policy of continuous improve ment also means that
is.shown.in.the.manual
sometimes. the. machine.
you.receive.will.be.slightly.different.than.what.
.
Woodstock International Technical Support Phone: (360) 734-3482 Email: [email protected]
We want your feedback on this manual. What did you like about it? Where could it be improved? Please take a few minutes to give us feedback.
If you find this to be the case, and the difference between the manual and machine leaves you confused about a procedure, check our website for an updated version. We post current manuals and manual updates for free on our website at
www.woodstockint.com
.
Technical Documentation Manager P.O. Box 2309 Bellingham, WA 98227 Email: [email protected]
Alternatively, you can call our Technical Support for help. Before calling, make sure you write down the
receipt Manufacture.Date
all Tech Support calls.
and available, have a copy of your
Serial.Number
original.purchase.
on hand. This information is required for from the machine ID label (see below). Also, if
MODEL XXXX MACHINE NAME Specifications WARNING!
Motor: Specification: Specification: Specification: Specification: Weight: To reduce risk of serious personal injury when using this machine: 1. Read & understand owner’s manual before operating.
2. Always wear approved eye protection and respirator.
3. Only plug power cord into a grounded outlet.
Manufacture
Date Serial Number Manufactured for Woodstock in Taiwan
Date
animal parts, biohazards, burning material/ashes, etc.
6. Do not expose to rain or wet areas.
7. Keep hands, long hair, and loose clothing away from inlet.
8. Never leave machine unattended while it is running.
9. Do not use if cord/plug becomes damaged—promptly
Serial Number
11. Always wear a respirator when emptying bags.
12. Prevent unauthorized use by children or untrained users.
-2-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Product Dimensions
MODEL W1839
6" VARIABLESPEED GRINDER WITH WORK LIGHT
Weight........................................................................................................... 28 lbs.
Width (side‐to‐side) x Depth (front‐to‐back) x Height................................... 15 x 12 x 17‐1/2 in.
Footprint (Length x Width)..................................................................... 11‐1/4 x 6‐3/4 in.
Shipping Dimensions
Type......................................................................................................... Cardboard Content........................................................................................................ Machine Weight........................................................................................................... 29 lbs.
Length x Width x Height........................................................................... 21 x 13 x 11 in.
Must Ship Upright.................................................................................................. Yes
Electrical
Power Requirement.................................................................... 120V, Single‐Phase, 60 Hz Full‐Load Current Rating........................................................................................ 2.5A
Minimum Circuit Size............................................................................................. 15A Power Cord Included.............................................................................................. Yes Power Cord Length............................................................................................... 6 ft.
Power Cord Gauge............................................................................................ 18 AWG Plug Included....................................................................................................... Yes Included Plug Type........................................................................................ NEMA 5‐15 Switch Type............................................................. Toggle Safety Switch w/Removable Key
Motors Main
Horsepower.............................................................................................. 1/3 HP Phase.............................................................................................. Single‐Phase Amps.......................................................................................................... 2.5
Speed......................................................................................... 2000 – 3400 RPM Type........................................................................ Capacitor‐Start Induction Motor Power Transfer ................................................................................... Direct Drive
Main Specifications Operation Info
Grinder Type.................................................................................. Variable‐Speed Wheel Type.................................................................................. Aluminum Oxide Right Wheel Diameter.................................................................................... 6 in.
Left Wheel Diameter...................................................................................... 6 in.
Right Wheel Grinding Face Width.................................................................... 3/4 in.
Left Wheel Grinding Face Width..................................................................... 3/4 in.
Wheel Bore.............................................................................................. 1/2 in.
Wheel Speed at Maximum Wheel Diameter..................................................... 4450 RPM Model W1839 Machine Specifications, Page 1 of 2 -3-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Construction
Base.................................................................................................... Cast Iron Work Rest............................................................................................ Aluminum Eye Shields........................................................................................ Clear Plastic Lamp.......................................................................................................... LED
Other
Country of Origin ............................................................................................... China Warranty ....................................................................................................... 2 Years Approximate Assembly & Setup Time ................................................................. 15 Minutes Serial Number Location .................................................................................... ID Label ISO 9001 Factory .................................................................................................. Yes Certified by a Nationally Recognized Testing Laboratory (NRTL) .......................................... No
Features
1/3 HP Variable‐Speed Induction Motor Dual 6" Aluminum‐Oxide Grinding Wheels 1/2" Grinding Wheel Bore 4450 RPM Grinding Wheel Speed Dual Eye Safety Shields Dual Adjustable Aluminum Work Rests Base Mounting Holes 3/8" (2) x 9‐7/8" OC -4 Model W1839 Machine Specifications, Page 2 of 2
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Product Dimensions
MODEL W1840
8" VARIABLESPEED GRINDER WITH WORK LIGHT
Weight........................................................................................................... 40 lbs.
Width (side‐to‐side) x Depth (front‐to‐back) x Height................................... 15‐1/2 x 12 x 19 in.
Footprint (Length x Width)..................................................................... 11‐1/4 x 6‐3/4 in.
Shipping Dimensions
Type.................................................................................................... Cardboard Box Content........................................................................................................ Machine Weight........................................................................................................... 43 lbs.
Length x Width x Height........................................................................... 22 x 15 x 13 in.
Must Ship Upright.................................................................................................. Yes
Electrical
Power Requirement.................................................................... 120V, Single‐Phase, 60 Hz Full‐Load Current Rating........................................................................................... 5A Minimum Circuit Size............................................................................................. 15A Power Cord Included.............................................................................................. Yes Power Cord Length............................................................................................... 6 ft.
Power Cord Gauge............................................................................................ 18 AWG Plug Included....................................................................................................... Yes Included Plug Type........................................................................................ NEMA 5‐15 Switch Type............................................................. Toggle Safety Switch w/Removable Key
Motors Main
Horsepower.............................................................................................. 3/4 HP Phase.............................................................................................. Single‐Phase Amps........................................................................................................... 5A Speed......................................................................................... 2000 – 3400 RPM Type........................................................................ Capacitor‐Start Induction Motor Power Transfer ................................................................................... Direct Drive
Main Specifications Operation Info
Grinder Type.................................................................................. Variable‐Speed Wheel Type.............................................................................................. Type 1 Right Wheel Diameter.................................................................................... 8 in.
Left Wheel Diameter...................................................................................... 8 in.
Right Wheel Grinding Face Width....................................................................... 1 in.
Left Wheel Grinding Face Width........................................................................ 1 in.
Wheel Bore.............................................................................................. 5/8 in.
Wheel Speed at Maximum Wheel Diameter..................................................... 3600 RPM Model W1840 Machine Specifications, Page 1 of 2 -5-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Construction
Base.................................................................................................... Cast Iron Work Rest............................................................................................ Aluminum Eye Shields........................................................................................ Clear Plastic Lamp.......................................................................................................... LED
Other
Country of Origin ............................................................................................... China Warranty ....................................................................................................... 2 Years Approximate Assembly & Setup Time ................................................................. 15 Minutes Serial Number Location .................................................................................... ID Label ISO 9001 Factory .................................................................................................. Yes Certified by a Nationally Recognized Testing Laboratory (NRTL) .......................................... No
Features
3/4 HP Variable‐Speed Induction Motor Dual 8" Aluminum‐Oxide Grinding Wheels 5/8" Grinding Wheel Bore 3600 RPM Grinding Wheel Speed Dual Eye Safety Shields Dual Adjustable Aluminum Work Rests Base Mounting Holes 3/8" (2) x 9‐7/8" OC Model W1840 Machine Specifications, Page 2 of 2 -6-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Controls.&.Components
Become familiar with the names and locations of the controls and features shown below to better understand the instructions in this manual.
B C A D E H G F Figure 1. W1839 & W1840 controls and components.
C. LED
when machine is turned ON/OFF.
For. Your. Own. Safety. Read. Instruction.
Manual.Before.Operating.Grinder
a). Replace.cracked.wheel.immediately.
b).Always.use.guards.and.eye.shields.
c). Do.not.overtighten.wheel.nut.
d).Only.use.flanges.furnished.with.grinder.
e).Adjust.work.rest.to.maintain.
1 ⁄ 16 ".–.
1 ⁄ 8 ".
distance.from.wheel.as.diameter.of.
wheels.will.decrease.with.use..DO.NOT.
allow.more.than.
1 ⁄ 8 ".gap.between.work.
rest.and.wheel.
f). Frequently.clean.grinding.dust.from.
beneath.grinder.
A. Safety Shield: Helps protect operator from sparks during grinding. Shield is not a substitute for proper personal protective equipment.
B. Spark Deflector: Helps contain sparks inside wheel guard to reduce operator exposure.
D. Wheel Guard: Prevents accidental contact with grinding wheel, and contains sparks during grinding.
E. Tool Rest (Right): Provides flat surface to rest workpiece during operation. Tilt angle is adjustable.
F. ON/OFF Switch w/Disabling Key: Turns motor ON when flipped up; turns motor OFF when pressed down. Key prevents motor from starting when removed.
G. Variable-Speed Dial: Controls grinding wheel speed. Turn clockwise to increase speed; turn counterclockwise to decrease speed.
H. Tool Rest (Left): Provides a 60 Tilt angle is adjustable.
° "V" shaped groove for sharpening drill bits. Also includes a flat surface for general grinding. -7-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
SAFETY
For.Your.Own.Safety, Read.Manual.Before.Operating.Machine
The. purpose. of. safety. symbols. is. to. attract. your. attention. to. possible. hazardous. conditions.. This.
manual.uses.a.series.of.symbols.and.signal.words.intended.to.convey.the.level.of.importance.of.the.
safety.messages..The.progression.of.symbols.is.described.below..Remember.that.safety.messages.by.
themselves.do.not.eliminate.danger.and.are.not.a.substitute.for.proper.accident.prevention.mea sures—this.responsibility.is.ultimately.up.to.the.operator!
Indicates.an.imminently.hazardous.situation.which,.if.not.avoided,.
WILL.result.in.death.or.serious.injury.
Indicates.a.potentially.hazardous.situation.which,.if.not.avoided,.
COULD.result.in.death.or.serious.injury.
NOTICE
Indicates.a.potentially.hazardous.situation.which,.if.not.avoided,.
MAY.result.in.minor.or.moderate.injury.
This.symbol.is.used.to.alert.the.user.to.useful.information.about.
proper.operation.of.the.equipment.or.a.situation.that.may.cause.
damage.to.the.machinery.
OWNER’S.MANUAL..
Read and understand this owner’s manual BEFORE using machine.
TRAINED.OPERATORS.ONLY..
Untrained operators have a higher risk of being hurt or killed. Only allow trained/supervised people to use this machine. When machine is not being used, disconnect power, remove switch keys, or lock-out machine to prevent unauthorized use—especially around children. Make workshop kid proof!
DANGEROUS.ENVIRONMENTS..
accidents and injury.
Do not use machinery in areas that are wet, cluttered, or have poor lighting. Operating machinery in these areas greatly increases the risk of
MENTAL.ALERTNESS.REQUIRED..
distracted.
Full mental alertness is required for safe operation of machinery. Never operate under the influence of drugs or alcohol, when tired, or when
ELECTRICAL.EQUIPMENT.INJURY.RISKS..
You can be shocked, burned, or killed by touching live electrical components or improperly grounded machinery. To reduce this risk, only allow an electrician or qualified service personnel to do electrical installation or repair work, and always disconnect power before accessing or exposing electrical equipment.
DISCONNECT.POWER.FIRST..
electrical components.
Always disconnect machine from power supply BEFORE making adjustments, changing tooling, or servicing machine. This eliminates the risk of injury from unintended startup or contact with live
EYE.PROTECTION..
glasses.
Always wear ANSI-approved safety glasses or a face shield when operating or observing machinery to reduce the risk of eye injury or blindness from flying particles. Everyday eyeglasses are not approved safety -8-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
WEARING.PROPER.APPAREL..
of workpiece control.
Do not wear clothing, apparel, or jewelry that can become entangled in moving parts. Always tie back or cover long hair. Wear non-slip footwear to avoid accidental slips, which could cause loss
HAZARDOUS.DUST..
Dust created while using machinery may cause cancer, birth defects, or long-term respiratory damage. Be aware of dust hazards associated with each workpiece material, and always wear a NIOSH-approved respirator to reduce your risk.
HEARING.PROTECTION..
Always wear hearing protection when operating or observing loud machinery. Extended exposure to this noise without hearing protection can cause permanent hearing loss.
REMOVE.ADJUSTING.TOOLS..
Tools left on machinery can become dangerous projectiles upon startup. Never leave chuck keys, wrenches, or any other tools on machine. Always verify removal before starting!
INTENDED.USAGE..
Only use machine for its intended purpose—never make modifications without prior approval from Woodstock International. Modifying machine or using it differently than intended will void the warranty and may result in malfunction or mechanical failure that leads to serious personal injury or death!
AWKWARD.POSITIONS..
Keep proper footing and balance at all times when operating machine. Do not overreach! Avoid awkward hand positions that make workpiece control difficult or increase the risk of accidental injury.
CHILDREN.&.BYSTANDERS..
distraction.
Keep children and bystanders at a safe distance from the work area. Stop using machine if they become a
GUARDS.&.COVERS..
Guards and covers reduce accidental contact with moving parts or flying debris—make sure they are properly installed, undamaged, and working correctly.
FORCING.MACHINERY..
Do not force machine. It will do the job safer and better at the rate for which it was designed.
NEVER.STAND.ON.MACHINE..
Serious injury may occur if machine is tipped or if the cutting tool is unintentionally contacted.
STABLE.MACHINE..
Unexpected movement during operation greatly increases risk of injury or loss of control. Before starting, verify machine is stable and mobile base (if used) is locked.
USE.RECOMMENDED.ACCESSORIES..
Consult this owner’s manual or the manufacturer for recommended accessories. Using improper accessories will increase risk of serious injury.
UNATTENDED.OPERATION..
To reduce the risk of accidental injury, turn machine running while unattended.
OFF
and ensure all moving parts completely stop before walking away. Never leave machine
MAINTAIN.WITH.CARE..
or death. Follow all maintenance instructions and lubrication schedules to keep machine in good working condition. A machine that is improperly maintained could malfunction, leading to serious personal injury
CHECK.DAMAGED.PARTS..
operating machine.
Regularly inspect machine for any condition that may affect safe operation. Immediately repair or replace damaged or mis-adjusted parts before
MAINTAIN.POWER.CORDS..
When disconnecting cord-connected machines from power, grab and pull the plug—NOT the cord. Pulling the cord may damage the wires inside, resulting in a short. Do not handle cord/plug with wet hands. Avoid cord damage by keeping it away from heated surfaces, high traffic areas, harsh chemicals, and wet/damp locations.
EXPERIENCING.DIFFICULTIES..
If at any time you experience difficulties performing the intended operation, stop using the machine! Contact Technical Support at (360) 734-3482.
-9-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Additional.Safety.for.Benchtop.Grinders
Serious.injury.or.death.can.occur.from.impact.injuries.if.a.grinding.wheel.breaks.apart.during.
operation..Rotating.grinding.wheels.can.easily.remove.skin.or.cause.entanglement.injuries.if.
clothing.or.apparel.is.caught.in.moving.parts..Fingers.can.be.pinched/cut.by.in-running.pinch.points..
Flying.sparks.can.ignite.explosive.or.flammable.materials..To.minimize.risk.of.injury.or.death,.
anyone.operating.machine.MUST.completely.heed.hazards.and.warnings.below.
SAFE MOUNTING & WORK AREA. An unsecured grinder may become dangerously out of control during operation. Before use, verify grinder is FIRMLY secured in a location free of explosive or flammable materials.
STARTING GRINDER. If a wheel is damaged, it will usually fly apart shortly after start-up. To protect yourself, always stand to side of grinder when turning it ON and allow it to run for at least one minute before standing in front of it.
SIDE & TOP GRINDING. Grinding on side of wheels can cause them to crack and burst— unless wheel is rated for side grinding. Grinding on top of wheels greatly increases risk of workpiece kickback. Always grind on downward part of wheel.
SPINDLE NUT. Only tighten wheel spindle nut enough to drive wheel and prevent slippage.
VISUAL INSPECTION. Verify that grinding wheels are free of cracks, chips, or dents in wheel surface before installing. Do not use wheel if it has any of these problems or it could break apart during operation.
WHEEL SPEED RATING. Before mounting a new wheel, be sure wheel RPM rating is equal to or higher than speed of grinder. Never use unmarked wheels or wheels rated for lower RPM than grinder.
EYE SHIELDS. Place eye shields close to grinding wheel and re-adjust as wheel wears down.
HAND & WHEEL CONTACT. Keep a firm grip on workpiece and position your hands a safe distance away when grinding. Anticipate when workpiece will heat up, and cool it before it becomes too hot to hold, or use an appropriate clamp. Avoid wearing gloves as they may get caught in grinding wheel and cause even more serious entanglement injuries.
VIBRATING WHEEL. Never use a wheel that vibrates excessively. Replace wheel or shaft bearings immediately.
SPARK DEFLECTOR GAP. Never allow gap between end of spark deflector and grinding wheel to exceed 1 ⁄ 4 ”. If the gap is larger, additional sparks and abrasives will be expelled toward the operator, which will increase the risk of injury.
TOOL REST POSITION. A large distance (gap) between tool rest and wheel increases risk of workpiece being pinched between wheel and tool rest causing wheel breakage, loss of control, and possible injury. Never allow gap between tool rest and wheel to exceed 1 ⁄ 8 ”. Replace grinding wheel when tool rest gap becomes wider than 1 ⁄ 8 ″ and no additional adjustment can be made to tool rest.
WHEEL FLANGES. Only use flanges included with or designed for this grinder when mounting wheels. Other flanges may not properly secure wheel and cause an accident. Do not use warped or damaged flanges, and always use paper discs (blotters) between wheels and flanges to reduce risk of flanges cracking wheel when tightening.
EYE, FACE, & LUNG PROTECTION. Grinding ejects small particles at a high rate of speed. These particles can cause blindness, skin injuries or respiratory damage. ALWAYS wear approved clothing, safety goggles, face shield, and a respirator for type of grinding to be done.
RING TEST. Perform a “ring test” on grinding wheels before installation to ensure they are safe to use. A wheel that does NOT pass ring test may break or fly apart during operation.
-10-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
ELECTRICAL
Circuit.Requirements
This machine must be connected to the correct size and type of power supply circuit, or fire or electrical damage may occur. Read through this section to determine if an adequate power supply circuit is available. If a correct circuit is not available, a qualified electrician MUST install one before you can connect the machine to power.
The. machine. must. be. properly. set. up.
before. it. is. safe. to. operate.. DO. NOT.
connect. this. machine. to. the. power.
source.until.instructed.to.do.so.later.in.
this.manual.
A power supply circuit includes all electrical equipment between the breaker box or fuse panel in the building and the machine. The power supply circuit used for this machine must be sized to safely handle the full load current drawn from the machine for an extended period of time. (If this machine is connected to a circuit protected by fuses, use a time delay fuse marked D.)
Full-Load.Current.Rating
The full-load current rating is the amperage a machine draws at 100% of the rated output power. On machines with multiple motors, this is the amperage drawn by the largest motor or sum of all motors and electrical devices that might operate at one time during normal operations.
W1839.Full-Load.Current.Rating.at.120V......... 2.5.Amps
W1840.Full-Load.Current.Rating.at.120V............5.Amps
Circuit.Requirements.for.120V
This machine is prewired to operate on a power supply circuit that has a verified ground and meets the following requirements:
Circuit.Type................ 110V/120V,.60.Hz,.Single-Phase Circuit.Size.............................................. 15.Amps
Plug/Receptacle..................................... NEMA.5-15 Incorrectly. wiring. or. grounding. this.
machine.can.cause.electrocution,.fire,.
or.machine.damage..To.reduce.this.risk,.
only.an.electrician.or.qualified.service.
personnel. should. do. any. required.
electrical.work.on.this.machine.
NOTICE
The.circuit.requirements.listed.in.this.
manual. apply. to. a. dedicated. circuit— where.only.one.machine.will.be.running.
at. a. time.. If. this. machine. will. be.
connected. to. a. shared. circuit. where.
multiple.machines.will.be.running.at.the.
same.time,.consult.with.an.electrician.
to. ensure. that. the. circuit. is. properly.
sized.for.safe.operation.
-11-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Grounding.Requirements
This machine MUST be grounded. In the event of certain types of malfunctions or breakdowns, grounding provides a path of least resistance for electric current to travel—in order to reduce the risk of electric shock.
Improper connection of the equipment-grounding wire will increase the risk of electric shock. The wire with green insulation (with/without yellow stripes) is the equipment grounding wire. If repair or replacement of the power cord or plug is necessary, do not connect the equipment grounding wire to a live (current carrying) terminal.
Check with a qualified electrician or service personnel if you do not understand these grounding requirements, or if you are in doubt about whether the tool is properly grounded. If you ever notice that a cord or plug is damaged or worn, disconnect it from power, and immediately replace it with a new one.
For.120V.Connection.
This machine is equipped with a power cord that has an equipment-grounding wire and NEMA 5-15 grounding plug. The plug must only be inserted into a matching receptacle (see
Figure
) that is properly installed and grounded in accordance with local codes and ordinances.
Extension.Cords
We do not recommend using an extension cord with this machine. Extension cords cause voltage drop, which may damage electrical components and shorten motor life. Voltage drop increases with longer extension cords and smaller gauge sizes (higher gauge numbers indicate smaller sizes).
Any extension cord used with this machine must contain a ground wire, match the required plug and receptacle, and meet the following requirements:
Minimum.Gauge.Size.at.120V....................... 16.AWG
Maximum.Length.(Shorter.is.Better).................50.ft.
120V GROUNDED 5-15 RECEPTACLE
Grounding Prong
5-15 PLUG
Neutral Hot
Figure.2.
NEMA 5-15 plug & receptacle.
DO. NOT. modify. the. provided. plug. or.
use. an. adapter. if. the. plug. will. not.
fit. the. receptacle.. Instead,. have. an.
electrician.install.the.proper.receptacle.
on. a. power. supply. circuit. that. meets.
the.requirements.for.this.machine.
-12-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
SETUP
Unpacking
This machine has been carefully packaged for safe transportation. If you notice the machine has been damaged during shipping, please contact your authorized Shop Fox dealer immediately.
Items.Needed.for.Setup
The following items are needed, but not included, to set up your machine.
Description.
• Mounting Hardware (
Qty
• Safety Glasses for Each Person ..........................1
• Degreaser or Solvent for Cleaning .......... As Needed • Disposable Rags for Cleaning ................ As Needed Page 15) ............... As Needed • Phillips Screwdriver #2 ...................................1
• Open-End Wrench 13mm .................................1
This machine presents serious injury hazards to untrained users. Read through this entire manual to become familiar with the controls and opera tions before starting the machine!
Wear safety glasses during entire setup process!
SUFFOCATION HAZARD!
Immediately discard all plastic bags and packing materials to eliminate c h o k i n g / s u f f o c a t i o n hazards for children and animals.
-13-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Inventory
The following is a list of items shipped with your machine. Before beginning setup, lay these items out and inventory them. Note:
If you cannot find an item on this list, carefully check around/inside the machine and packaging materials. Often, these items get lost in packaging materials while unpacking or they are pre-installed at the factory.
SUFFOCATION HAZARD!
Immediately discard all plastic bags and packing materials to eliminate c h o k i n g / s u f f o c a t i o n hazards for children and animals.
Box.Contents.(Figure.3):.
A..
Qty
Grinder (not shown) .......................................1
B..
Tool Rest Bracket (Right) .................................1
C.
Tool Rest Bracket (Left) ..................................1
D..
Tool Rest (Left) ............................................1
E..
Tool Rest (Right) ...........................................1
F.
Spark Deflector (Right) ...................................1
G.
Spark Deflector (Left) ....................................1
H.
Safety Shield Mounting Brackets ........................2
I..
J..
Safety Shield Mounting Plates ...........................2
Spark Deflectors ...........................................2
B C D J E H I F G
Hardware.(Figure.4): K..
.
Qty
Flat Washers 8mm .........................................2
L..
Flat Washers 6mm .........................................4
M.
Flat Washers 5mm .........................................4
N.
Lock Washers 6mm ........................................4
O.
Lock Washers 5mm ........................................4
P..
Q..
Hex Bolts M8-1.25 x 12 ...................................4
Phillips Head Screws M4-.7 x 12 ........................4
R.
Carriage Bolts M6-1 x 12 .................................2
S.
Phillips Head Screws M5-.8 x 10 ........................4
T..
Flange Nuts M4-.7 .........................................4
U..
V..
Knobs M6-1 .................................................2
Knob Bolts M6-1 x 18 ......................................2
Figure.3.
Tool rest and safety shield parts.
K P Q L M R N S U V
Figure.4..
Fastener inventory.
O T -14-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Machine.Placement
Workbench.Load
Refer to the
Machine.Specifications
for the weight and footprint specifications of your machine. Some workbenches may require additional reinforcement to support the weight of the machine and workpiece materials.
Placement.Location
Consider anticipated workpiece sizes and additional space needed for auxiliary stands, work tables, or other machinery when establishing a location for this machine in the shop. Below is the minimum amount of space needed for the machine.
Mount the grinder to a workbench to avoid accidental tipping. For portable bench grinding, mount it to a heavy plywood base (at least 1" thick) that is wide enough to prevent tipping or rocking during use.
Bench.Mounting
Number.of.Mounting.Slots.........................2
Diameter.of.Mounting.Hardware.Needed...
3 ⁄ 8 "
The base of this machine has mounting holes that allow it to be fastened to a workbench or other mounting surface to prevent it from moving during operation and causing accidental injury or damage. The strongest mounting option is a “Through Mount” (see example) where holes are drilled all the way through the workbench—and hex bolts, washers, and hex nuts are used to secure the machine in place.
Hex Bolt 15"
Figure 5 .
W1839 minimum working clearances.
Flat Washer
Machine Base Workbench
Flat Washer Lock Washer Hex Nut
Figure.7.
Typical "Through Mount" setup.
Another option is a “Direct Mount” (see example) where the machine is secured directly to the workbench with lag screws and washers.
Lag Screw 15 1 / 2 "
Figure 6 .
W1840 minimum working clearances.
-15 Flat Washer
Machine Base Workbench Figure.8.
Typical "Direct Mount" setup.
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Assembly
Before beginning the assembly process, refer to
Items.
Needed.for.Setup
and gather everything you need. Ensure all parts have been properly cleaned of any heavy-duty rust-preventative applied at the factory (if applicable). Be sure to complete all steps in the assembly procedure prior to performing the
Test.Run
.
To.assemble.machine,.do.these.steps: 1..
Assemble safety shields (see
Figure 9
) using (4) M4-.7 x 12 Phillips head screws, (4) M4-.7 flange nuts, (2) safety shield mounting plates, (2) safety shields, and (2) safety shield mounting brackets.
2..
Attach safety shield assemblies to spark deflectors (see Figure 10) using (2) M6-1 x 12 carriage bolts, (2) 6mm flat washers, and (2) M6-1 knobs.
Safety Shield Safety Shield Mounting Bracket Phillips Head Screws Flange Nuts
Figure.9.
Safety shield components.
Safety Shield Assembly Carriage Bolt Safety Shield Mounting Plate Knob Flat Washer Spark Deflector
Figure.10.
Safety shield attached to spark deflectors (1 or 2).
3..
Attach each spark deflector/safety shield assembly to grinder with (4) M5-.8 x 10 Phillips head screws, (4) 5mm flat washers, and (4) 5mm lock washers (see Figure 11).
4..
Assemble left tool rest using (1) left tool rest bracket, (1) left tool rest, (1) 6mm flat washer, (1) 6mm lock washer, and (1) M6-1 x 18 knob bolt (see Figure 12).
5..
Assemble right tool rest using (1) right tool rest bracket, (1) right tool rest, (1) 6mm flat washer, (1) 6mm lock washer, and (1) M6-1 x 18 knob bolt.
x 2
Figure.11.
Spark deflector attached.
Lock Washer Tool Rest Tool Rest Bracket Flat Washer Knob Bolt
Figure.12.
Tool rest assembly.
-16-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
6..
Attach each tool rest assembly to grinder using (4) M8-1.25 x 12 hex bolts and (4) 8mm flat washers (see
Figure 13
).
Some grinding wheels must be replaced before spark deflector or tool rest reach their final adjustment. As diameter of a grinding wheel is reduced, so is surface speed. Grinding under these conditions can lead to faster abrasive loss and poor grinding results. Always follow wheel manufacturer's directions.
Figure.13.
Tool rest assembly attached to grinder.
Tool.Rest.Adjustment
The toll rest can be adjusted closer/farther from grinding wheel or tilted and secured every 15 ° from 0 ° —75 °.
The tool rest stabilizes the workpiece when grinding. It must always be positioned correctly when using the grinder to help prevent the operator's hands from being pulled into grinding wheel. Each tool rest features detents that allow it to lock at a specific angle. To adjust a tool rest, loosen the knob bolt (see
Figure 13).
several turns, pivot the tool rest to the appropriate angle, position it 1 ⁄ 16 " away from the grinding wheel, and then tighten knob bolt to secure setting.
As grinding wheel wears, shift tool rest closer to grinding wheel to maintain a gap of 1 ⁄ 16 " – 1 ⁄ 8 " (see
Figure 14
). IMPORTANT: If the gap reaches
operating grinder.
1 ⁄ 8 " and the tool rest cannot be adjusted any closer to the wheel, the grinding wheel MUST be replaced before you can resume safely
Spark.Deflector.Adjustment
The spark deflector prevents sparks from showering the top of the workpiece and the operator's hands. As the wheel wears, adjust the spark deflector closer to the grinding wheel to maintain a gap of 1 ⁄ 8 " – 1 ⁄ 4 " (see
Figure 15
). If the gap reaches 1 ⁄ 4 " and no additional adjustments can be made, replace the grinding wheel.
1 ⁄ 16 " – 1 ⁄ 8 " Knob Bolt
Figure.14.
Tool rest gap.
1 ⁄ 8 " – 1 ⁄ 4 "
Figure.15.
Spark deflector gap.
Never grind
WITHOUT
tool rest in place and properly positioned. "Free hand" grinding or too large of a gap between wheel and tool rest increases risk of pinching, which may result in wheel breakage or operator injury.
-17-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Test.Run
Once assembly is complete, test run the machine to ensure it is properly connected to power and safety components are functioning properly.
If you find an unusual problem during the test run, immediately stop the machine, disconnect it from power, and fix the problem BEFORE operating the machine again. The
Troubleshooting
table in the
SERVICE
section of this manual can help.
To.test.run.machine,.do.these.steps: 1.
Clear all setup tools away from machine.
2.
Connect machine to power supply.
3.
Rotate variable-speed dial all the way left and turn machine machine
ON
, verify motor operation, and slowly rotate variable-speed dial to the right, then turn
OFF
.
The motor should run smoothly and without unusual noises.
4.
Remove key from toggle switch (see
Figure 16
).
5.
Try to start machine with switch.
Machine should NOT start. If it switch must be replaced.
does
start, the switch disabling feature is not functioning properly and the
Serious. injury. or. death. can. result.
from. using. this. machine. BEFORE.
understanding. its. controls. and. related.
safety.information..DO.NOT.operate,.or.
allow.others.to.operate,.machine.until.
the.information.is.understood..
DO. NOT. start. machine. until. all.
preceding.setup.instructions.have.been.
performed..Operating.an.improperly.set.
up. machine. may. result. in. malfunction.
or. unexpected. results. that. can. lead.
to. serious. injury,. death,. or. machine/ property.damage.
Figure.16.
Removing switch key from toggle switch.
-18-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
OPERATIONS
Operation.Overview
This machine will perform many types of operations that are beyond the scope of this manual. Many of these operations can be dangerous or deadly if performed incorrectly.
The instructions in this section are written with the understanding that the operator has the necessary knowledge and skills to operate this machine. If at any time you are experiencing difficulties performing any operation, stop using the machine!
To. reduce. your. risk. of. serious. injury.
or. damage. to. the. machine,. read. this.
entire.manual.BEFORE.using.machine.
The overview below provides the novice machine operator with a basic understanding of how the machine is used during operation, so the machine controls/components discussed later in this manual are easier to understand. Due to its generic nature, this overview is
NOT
intended to be an instructional guide.
To complete a typical operation, the operator does the following:
1. Ensures workpiece is suitable for grinding.
2. Selects correct grinding wheel for operation, inspects wheel, performs a "ring test," and installs wheel.
3. Verifies/adjusts tool rest position so gap is perpendicular and between 1 ⁄ 8 "— 1 ⁄ 4 ".
1 ⁄ 16 "— 1 ⁄ 8 " from grinding wheel, and verifies/adjusts spark deflector and wheel gap is 4. Positions safety shield for safe grinding.
5. Ensures that ON/OFF switch is in OFF position and variable-speed dial is turned all the way left, then connects grinder to power.
6. Puts on personal protective equipment.
7. Stands aside, starts grinder, and allows it to reach full speed and operate for at least one minute to ensure grinding wheel does not fly apart from the centrifugal force of rotation.
8. Positions workpiece on tool rest for grinding.
To. reduce. the. risk. of. eye. injury. and.
long-term. respiratory. damage,. always.
wear. safety. glasses. and. a. respirator.
while.operating.this.machine.
If you are an inexperienced operator, we strongly recommend that you read books or trade articles, or seek training from an experienced operator of this type of machinery before performing unfamiliar operations. must.come.first!
Above.all,.safety.
9. Operator gradually feeds workpiece into grinding wheel and moves workpiece left and right to prevent grooves in wheel.
10. Quenches workpiece as required to prevent surface hardening or temper loss.
11. Stops bench grinder.
-19-
Workpiece.Inspection
Some workpieces are not suitable for grinding on a bench grinder.
Before grinding, inspect all workpieces for the following:
• Hard Workpiece:
Workpieces that are made of stone, carbide, stainless steel, ceramics, glass, or have hardened welds will wear out most general-grade grinding wheels quickly. If hard materials are to be ground, you must install the correct type of grinding wheel.
• Soft Workpiece:
Workpieces that are made of aluminum, brass, lead, and other non ferrous metals will load up in the grinding wheel and render the abrasive useless. Grinding wood, plastics, rubber, fiberglass, or other soft materials can also cause the same problem and lead to the wheel over heating and possibly bursting during use if ignored. To restore a loaded grinding wheel surface, redress with a dressing tool.
• Flexible/Unstable Workpiece:
avoided.
Grinding on the side or the ends of cable, chain, or round workpieces creates the hazard of workpiece twist or grab, leading to entanglement with the wheel or shaft. This hazard must be
• Loose Parts:
Make sure that the workpiece is free of any parts like springs, pins, balls, or other components that may loosen or dis lodge during grinding, and hit the operator.
• Strength:
Make sure that the workpiece is strong enough to be ground. Should it break, the broken piece may dig into the wheel and cause kickback or severe injury.
Electrical system is not waterproof. DO NOT use grinder with liquid cooling system for wet grinding. Ignoring warning can lead to electrocution or machine damage.
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
with a 1
Wheel.Selection
The Model W1839 only accepts Type-1 wheels ⁄ 2 " bore. The W1840 only accepts Type-1 wheels with a 5 ⁄ 8 " bore.
Aluminum oxide and silicon carbide wheels are marked in a somewhat uniform manner by all the major manufacturers. Understanding these markings will help you understand the capa bilities of various wheels. Always refer to the manufacturer’s grinding recommendations when selecting a wheel for your project.
The basic format for wheel numbering is:
Prefix 1 Abrasive Type A Grit Size Grade 60 L Bond Type V The Prefix is the manufacturer’s designation for a particular wheel type (e.g. Type-1 wheels).
The most common Abrasive Types used are A for Aluminum Oxide, C for Silicon Carbide, and occasionally SG for Seeded Gel.
The Grit Size is a number that refers to the size of the abrasive grain in the wheel. The lower the number, the coarser the wheel. Ten is a very coarse wheel for roughing, and 220 is usually the upper range for fine finish work.
Grade is an indication of the hardness of the wheel—“A” being the softest and “Z” being the hardest.
Bond Type refers to the type of bonding material used to hold the abrasive material. Most general purpose wheels will have a “V” indicating Vitrified Clay is used. Vitrified Clay provides high strength and good porosity. The other common bond type is “B” for resin where synthetic resins are used. These are used to grind cemented carbide and ceramic materials.
Note: There may be other numbers inserted
that have meaning for a particular type of wheel. Refer to the manufacturer’s technical data for a complete explanation.
-20-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Wheel.Inspection
Before mounting a new grinding wheel, it must be inspected. Do not assume that a wheel is in sound condition just because it is new—often, damage can occur in shipping, with age, or with exposure to moisture. First, do a Visual Inspection. Look for any cracks, chips, nicks, or dents in the surface of the wheel. If you see any of these, DO NOT use the wheel. Second, do a Ring Test. This test will give you an indication of any internal damage that may not be obvious during a visual inspection.
To perform ring test, do these steps:
1. Make sure grinding wheel is clean and dry; otherwise, you may get false results.
2. Hang wheel in air with a piece of cord or string looped through mounting hole in center.
3. At spots shown in Figure 17, gently tap grinding wheel with a light non-metallic device such as handle of a screwdriver or a wooden mallet.
Note: Finding exact spot to tap may take several
attempts.
4. An undamaged grinding wheel will emit a clear metallic ring or “ping” sound in each of these spots. A damaged grinding wheel will respond with a dull thud that has no clear tone. — If you determine from the ring test that a grinding wheel is damaged, DO NOT use it!
STOP Rated 3500 RPM Make sure your grinder is not faster than the rated RPM of this wheel Type-1 Aluminum Oxide 60 Grit Grade L Vitrified Bond WARNING Grinding can be dangerous Visually inspect this wheel for cracks, nicks,chips Figure 17. Tapping locations when performing a ring test.
Warped wheel flanges can increase risk of grinding wheel breaking and flying apart. Never use warped wheel flanges. Always check flanges for flat ness before installing grinding wheel.
-21-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Wheel.Care
When grinding, your safety depends, to a large degree, on the condition of the wheel. A wheel in poor condition could break apart during rotation and injure the operator and others in the area.
Here are some tips to help you avoid breaking the wheel:
• Always transport, store and handle wheels with care. Wheels may be damaged if they are dropped or if heavy objects are stacked on them.
• Select the right grinding wheel for the job. DO NOT grind material inappropriate for the wheel type.
• Only use wheels that are rated for the RPM of the grinder.
• Mount the wheel properly (see
Wheel Removal &
Installation on Page 24). • Do not push the workpiece into the grinding wheel with such force that it causes the grinder to bog down. And do not apply pressure to stop the wheel after turning the grinder
OFF
.
• Dress the wheel when necessary. Do not allow it to become glazed (see Wheel Dressing on Page 23).
• Do not store wheels in damp or wet locations.
• Do not overtighten the nut when mounting the wheel.
-22-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Wheel.Dressing
Depending on the type of grinding you do, the grinding wheel may require periodic dressing. There are several different types of wheel dressing devices available on the market (see Accessories on Page 25 for examples). Dressing restores the abrasive quality of the wheel surface and brings the wheel edge back to square. Refer to the instructions that accompany your dressing accessory for complete details on how to properly dress the wheel.
To dress grinder wheel, do these steps:
1. Turn grinder
ON
.
2. Place wheel dresser on tool rest with dressing wheels facing toward grinding wheel.
3. Slowly move dressing wheel toward grinding wheel and maintain slight pressure until a clear, even grind ing surface appears across face of wheel.
4. Turn grinder
OFF
.
5. Adjust spark deflector and tool rest as shown on Page 17.
Always adjust the tool rest and spark deflector after dressing or replacing the grinding wheel. Failure to do so could lead to workpiece kickback and injury.
Tool Rest Grinder Wheel Wheel Dresser
Figure.21.
Example of dressing grinder wheel.
-23-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Wheel.Removal.&.
Installation
To remove and install grinding wheel, do these steps:
1. DISCONNECT MACHINE FROM POWER!
2. Remove outer guard by removing (3) knob bolts, (3) 6mm lock washers, and (3) 6mm flat washers that secure outer guard (see Figure 18).
3. Remove M16-2 hex nut ( see
Figure 19
) . Tip: Hold grinding wheel with free hand to stop it
from turning while loosening the hex nut.
Note: Nut on left side of grinder has left-hand
threads. Turn it clockwise to loosen.
4. Remove outer grinding wheel flange and paper disc.
5. Remove grinding wheel from spindle. Take note of paper or fiber disc between wheel flanges and wheel. These cushion the pressure of the wheel flanges and help distribute pressure more evenly. They also help reduce damage to the flanges.
6. Verify flatness of inner and outer flanges by placing them on a flat surface. If either flange is warped or damaged, replace it.
7. Mount new grinding wheel, as shown in Figure 20. Tighten M16-2 hex nut snugly but do not over tighten. Over-tightening can stress and crack wheel.
8. Re-assemble outer wheel guard using hardware removed in Step 2.
9. While standing away from line of rotation, turn grinder
ON
and run new grinding wheel for at least 1–2 minutes before standing in front of it. This helps protect you if the wheel has internal damage that will cause it to fly apart from the centrifugal force of rotation. — If grinder runs smoothly, grinding wheel may now be used.
— If wheel appears to wobble, grinder vibrates excessively, or any other unsafe condition appears with new wheel, stop grinder and refer to Troubleshooting on Page 27.
-24 Figure 18. Location of outer guard hardware that must be removed when removing wheel.
Outer Grinding Wheel Flange M16-2 Hex Nut Figure 19. Outer wheel guard removed.
NEVER assemble grinding wheel on spindle without paper or fiber discs between wheel and flange. Not using discs can put stress on wheel, causing it to crack and possibly fly apart.
Paper Discs 0 0 R P M A l uminumn Oxid Bon Outer Guard Paper Disc
Figure 20.
Assembly order for wheel installation.
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
ACCESSORIES
Grinder.Accessories
The following grinder accessories may be available through your local Woodstock International Inc. Dealer. If you do not have a dealer in your area, these products are also available through online dealers. Please call or e-mail Woodstock International Inc. Customer Service to get a current listing of dealers at: 1-800-840-8420 or at [email protected].
The
.D4144.
Shop Fox
.Drill.Sharpener
mounts next to your bench grinder and can sharpen drill bits from 1 ⁄ 8 " to 3 ⁄ 4 " with speed and accuracy. Adjustable for various drill-point angles.
The
D4141.Drill.Gauge.Set.
(A - Z) and fractional ( 1 ⁄ 16 " – offers 3 steel plates with clear markings, precision stamped gauge holes and lists numbered (1 – 60), lettered 1 ⁄ 2 " by 1 ⁄ 64 ") sized drill bits. Stop guess ing and check those drill sizes before you drill that hole! It even includes a tap drill/clearance drill reference chart.
The 8 1 ⁄ 2 D3744 STEELEX " long with a 3 3 ⁄ 4
.Diamond.Dresser.with.Handle
features a 0.25 carat diamond tip for trueing abrasive grinding wheels fast and easy while exposing a fresh surface for efficient grinding operations. Simply guide the Diamond Dresser against the grinder's tool rest to restore the wheel back to its original condition. Overall length is " long handle. The industrial diamond measures 0.25 carat.
-25-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
MAINTENANCE
Schedule
For optimum performance from your machine, follow this maintenance schedule and refer to any specific instructions given in this section.
Daily Check
• Loose mounting bolts.
• Cracked or loose grinding wheel.
• Worn or damaged wires.
• Any other unsafe condition.
MAKE. SURE. that. your. machine. is.
unplugged. during. all. maintenance. pro cedures!.If.this.warning.is.ignored,.seri ous.personal.injury.may.occur.
Grinding.Wheels
The grinding wheels should be inspected before every use. Use the ring test method noted in Wheel Inspection on Page 21 to verify the structural integrity. Take care in storing grinding wheels to keep them free from potential damage by being dropped or having other items drop on them. Replace the wheel when the spark deflector or tool rest has no more adjustment and the gap has exceeded the safe limit.
Cleaning.&.Protecting
Cleaning the grinder is relatively easy. Vacuum excess debris, and wipe off the remaining dust with a dry cloth.
Wheel.Storage
Grinding wheels can be easily damaged, so it is important to store them properly. Follow all wheel manufacturer storage instructions. Always store grinding wheels in a location that is dry and protected from potential damage due to them being dropped or having other items dropped on them. Also, avoid storing grinding wheels where there is high humidity, extreme heat or cold, or solvents.
Wheel.Dressing
Depending on the type of grinding you do, the grinding wheel may require periodic dressing. Dressing restores the abrasive quality of the wheel surface and squares up the wheel edge. Refer to the instructions that accompany your dressing accessory for complete details on how to properly dress a wheel.
-26-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
SERVICE
Troubleshooting
The following troubleshooting tables cover common problems that may occur with this machine. If you need replacement parts or additional troubleshooting help, contact our Technical Support. Note:
Before contacting Tech Support, find the machine serial number and manufacture date, and if available, your original purchase receipt. This information is required to properly assist you.
Motor.and.Electrical
PROBLEM POSSIBLE.CAUSE
CORRECTIVE.ACTION
Machine does not start or a breaker trips.
Machine has vibration or noisy opera tion.
1. Switch disabling key removed.
2. Incorrect power supply voltage or circuit size.
3. Power supply circuit breaker tripped or fuse blown. 4. Motor wires connected incorrectly.
5. Potentiometer/variable-speed dial controller at fault.
6. Circuit board at fault.
7. Motor at fault.
1. Install switch disabling key.
2. Ensure correct power supply voltage and circuit size. 3. Ensure circuit is sized correctly and free of shorts. Reset circuit breaker or replace fuse.
4. Correct motor wiring connections.
5. Test/replace.
6. Inspect/replace. 7. Test/repair/replace.
Machine stalls or is underpowered.
1. Machine undersized for task.
2. Motor wired incorrectly.
3. Motor overheated.
4. Run capacitor at fault.
5. Motor bearings at fault .
1. Machine incorrectly mounted to workbench or floor.
2. Motor or component loose.
3. Grinding wheel at fault/arbor hole not round.
4. Motor bearings at fault.
5. Motor shaft bent.
1. Use new grinding wheel; reduce feed rate/pres sure.
2. Wire motor correctly.
3. Clean motor, let cool, and reduce workload.
4. Test/repair/replace.
5. Test by rotating shaft; rotational grinding/loose shaft requires bearing replacement.
1. Adjust feet, shim, or tighten mounting hardware.
2. Inspect/replace damaged bolts/nuts, and re-tight en with thread-locking fluid.
3. Dress/replace grinding wheel ( Page 23).
4. Test by rotating shaft; rotational grinding/loose shaft requires bearing replacement.
5. Test with dial indicator and replace motor.
-27-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Operation
PROBLEM POSSIBLE.CAUSE
CORRECTIVE.ACTION
Machine slows when operat ing.
1. Operator applying too much pressure too 1. Slow down rate of movement of workpiece into quickly.
2. RPM too low.
wheel; use less pressure.
2. Adjust RPM. Wavy condition on surface of workpiece.
Burning spots or cracks in the workpiece.
Wheel dulls quickly, grit falls off.
1. Machine vibrating.
2. Workpiece not being held firmly.
3. Wheel face uneven.
4. Wheel is too hard.
Lines on surface of workpiece.
1. Impurity on wheel surface.
2. Workpiece not being held tightly.
1. Improper type of grinding wheel.
2. Improper feed rate.
3. Workpiece requires quenching.
1. Ensure machine is securely mounted to a solid sur face ( Page 15).
2. Use a holding device to firmly retain workpiece.
3. Dress grinding wheel ( Page 23).
4. Use softer wheel or reduce feed rate.
1. Dress grinding wheel ( Page 23).
2. Use a holding device to firmly retain workpiece.
1. Try a wheel with softer style or a coarser grit.
2. Slow down rate of movement of workpiece into wheel.
3. Quench workpiece in water to cool.
1. Operator applying too much pressure too 1. Slow down rate of movement of workpiece into quickly.
2. Wheel is too soft.
wheel; use less pressure.
2. Wheel too soft for material being ground, select 3. Wheel diameter too small.
4. Bad wheel dress.
5. Defective wheel bonding.
harder bond.
3. Replace grinding wheel ( Page 24).
4. Re-dress grinding wheel ( Page 23).
5. Replace grinding wheel. Consult manufacturer of grinding wheel.
-28-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Electrical.Safety.Instructions
These pages are current at the time of printing. However, in the spirit of improvement, we may make changes to the electrical systems of future machines. Compare the manufacture date of your machine to the one stated in this manual, and study this section carefully.
If there are differences between your machine and what is shown in this section, call Technical Support at (360) 734-3482 for assistance BEFORE making any changes to the wiring on your machine. An updated wiring diagram may be available.
Note:
Please gather the serial number and manufacture date of your machine before calling. This information can be found on the main machine label.
SHOCK.HAZARD.
Working on wiring that is connected to a power source is extremely dangerous. Touching electrified parts will result in personal injury including but not limited to severe burns, electrocution, or death. Disconnect the power from the machine before servicing electrical components!
QUALIFIED.ELECTRICIAN.
Due to the inherent hazards of electricity, only a qualified electrician should perform wiring tasks on this machine. If you are not a qualified electrician, get help from one before attempting any kind of wiring job.
WIRE.CONNECTIONS.
All connections must be tight to prevent wires from loosening during machine operation. Double-check all wires disconnected or connected during any wiring task to ensure tight connections.
WIRE/COMPONENT.DAMAGE..
completing the task.
Damaged wires or components increase the risk of serious personal injury, fire, or machine damage. If you notice that any wires or components are damaged while performing a wiring task, replace those wires or components before
MODIFICATIONS
. Using aftermarket parts or modifying the wiring beyond what is shown in the diagram may lead to unpredictable results, including serious injury or fire.
MOTOR.WIRING.
The motor wiring shown in these diagrams is current at the time of printing, but it may not match your machine. Always use the wiring diagram inside the motor junction box.
CAPACITORS/INVERTERS.
capacitors.
Some capacitors and power inverters store an electrical charge for up to 10 minutes after being disconnected from the power source. To reduce the risk of being shocked, wait at least this long before working on
CIRCUIT.REQUIREMENTS.
power source.
You MUST follow the requirements at the beginning of this manual when connecting your machine to a
EXPERIENCING.DIFFICULTIES.
(360) 734-3482.
If you are experiencing difficulties understanding the information included in this section, contact our Technical Support at
The photos and diagrams included in this section are best viewed in color. You can view these pages in color at www.shopfox.biz.
BLACK WHITE GREEN RED
WIRING DIAGRAM COLOR KEY
BLUE BROWN GRAY YELLOW YELLOW GREEN PURPLE ORANGE PINK LIGHT BLUE WHITE TUR-
-29-
120 Volt Motor
Ground
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Wiring.Diagram
Ground Wt
Rotation Sensor
Wt Wt Wt Wt Run Capacitor 45MFD 250VAC
Speed Control Potentiometer B103
Wt B103
Switch Panel (Viewed from Back) Safety Switch KEDU HY7
Wt Wt R27 E123995 U6 Wt T2/M F1 T1/M T2/N T10AL/250V T4/L Read Page 29
STOP
Before Wiring
Grinder Base (Viewed from Bottom) The motor wiring shown here is current at the time of printing, but it may not match your machine. Always use the wiring diagram inside the motor junction box.
Circuit Board Box (Viewed from Top)
Hot Neutral Wt Ground
120 VAC 5-15 Plug (Pre-Wired)
-30 Wt
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
PARTS
W1839.Main.Breakdown
69 15 13 24 36 22 74 30 44 77 76 29 75 45 46 26 43 71 47 40 39 38 37 73 53 42 41 12 29 22 77 76 23 24 16 47 71 19 17 18 44 30 15 27 18 20 21 52 51 50 46 49 48 11 25 42 54 5 10 9 8 81 7 78 79 1 4 5 3 2-1 65 28 66 80 55 56 2 6 57 58 63 20 18 67 31 29 18 68 70 64 61 63 59 14 62 60 33 34 47 72 71 71 47 35 34 33 32 29 31 -31-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
W1839.Parts.List
REF PART # DESCRIPTION
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 8 9 10 11 12 13 14 15 16 17 4 5 6 7 1 X1839001 LAMP CIRCUIT BOARD 2 X1839002 CIRCUIT BOARD E123995 2-1 X1839002-1 FUSE 10A 250V 5 X 20MM GLASS 3 X1839003 TAP SCREW M3 X 5 X1839004 X1839005 X1839006 X1839007 CIRCUIT BOARD COVER PHLP HD SCR M4-.7 X 8 W/CAPTIVE WASHER R CAPACITOR 30M 300V 1-3/8 X 3 BASE X1839008 X1839009 X1839010 X1839011 X1839012 X1839013 X1839014 X1839015 X1839016 X1839017 STRAIN RELIEF MOUNTING PLATE PHLP HD SCR M5-.8 X 10 STRAIN RELIEF TYPE-1 10MM POWER CORD 14G 3W 72" 5-15P FLAT WASHER 12MM LED LIGHT PHLP HD SCR M5-.8 X 8 KNOB BOLT M5-.8 X 10 3-LOBE OUTER WHEEL COVER (L) HEX NUT M12-1.75 LH X1839018 X1839019 X1839020 X1839021 X1839022 X1839023 X1839024 X1839025 X1839026 X1839027 X1839028 X1839029 X1839030 X1839031 X1839032 X1839033 X1839034 X1839035 X1839036 X1839037 X1839038 X1839039 X1839040 WHEEL FLANGE GRINDING WHEEL 6 X 1/2 X 3/4 AO60 PHLP HD SCR M5-.8 X 10 W/CAPTIVE WASHER INNER WHEEL COVER (L) CARRIAGE BOLT M6-1 X 12 SPARK DEFLECTOR (L) PHLP HD SCR M5-.8 X 10 W/CAPTIVE WASHER HEX NUT M4-.7
EYESHIELD (R) EYESHIELD (L) PHLP HD SCR M4-.7 X 8 FLAT WASHER 6MM KNOB M6-1 KNOB BOLT M6-1 X 14 3-LOBE TOOL REST (L) HEX BOLT M8-1.25 X 12 FLAT WASHER 8MM SUPPORT BRACKET (L) SPARK DEFLECTOR (R) MOTOR COVER (R) SET SCREW M5-.8 X 6 FEEDBACK WHEEL PHLP HD SCR M2.5-.45 X 6 X1839041 X1839042 X1839043 X1839044 X1839045 X1839046 X1839047 X1839048 X1839049 X1839050 X1839051 X1839052 X1839053 X1839054 X1839055 X1839056 X1839057 X1839058 X1839059 X1839060 X1839061 X1839062 X1839063 X1839064 X1839065 X1839066 X1839067 X1839068 X1839069 X1839070 X1839071 X1839072 X1839073 X1839074 X1839075 X1839076 X1839077 X1839078 X1839079 X1839080 X1839081
REF PART #
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81
DESCRIPTION
RPM SENSOR GROMMET HEX NUT M4-.7
LOCK WASHER 6MM INNER MOTOR COVER BALL BEARING 6202ZZ FLAT WASHER 5MM ROTOR STATOR WAVY WASHER 12MM MOTOR COVER (L) PHLP HD SCR M4-.7 X 145 W/CAPTIVE WASHER FLANGE NUT M4-.7
EXT TOOTH WASHER 4MM PHLP HD SCR M4-.7 X 16 WIRE CLIP PLASTIC PHLP HD SCR M6-1 X 18 W/CAPTIVE WASHER POTENTIOMETER B103 SWITCH MOUNTING PLATE TOGGLE SWITCH KEDU HY7 SPEED KNOB SPACER SPEED ADJ KNOB PHLP HD SCR M5-.8 X 16 W/CAPTIVE WASHER PHLP HD SCR M4-.7 X 8 W/CAPTIVE WASHER BASE PLATE RUBBER FOOT GRINDING WHEEL 6 X 1/2 X 3/4 AO36 HEX NUT M12-1.75
OUTER WHEEL COVER (R) TOOL REST (RIGHT) LOCK WASHER 5MM SUPPORT BRACKET (R) INNER WHEEL COVER (R) LED LENS LED COVER FLANGE NUT M4-.7
PHLP HD SCR M4-.7 X 10 L-BRACKET METAL HEX NUT M8-1.25
MACHINE ID LABEL TOUCH-UP PAINT, SHOP FOX WHITE -32-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
W1840.Main.Breakdown
13 74 30 44 29 77 76 75 36 24 22 45 46 26 43 39 40 47 71 38 37 53 73 42 41 20 18 67 18 68 31 29 70 33 69 15 34 12 52 29 22 24 77 76 23 16 47 71 18 17 44 30 27 19 18 20 21 47 51 50 46 49 47 48 11 10 9 81 7 8 42 54 5 78 79 4 5 3 25 15 1 28 2-1 55 56 6 65 66 80 44 57 2 71 47 35 34 33 32 29 31 47 58 61 64 63 59 14 62 60 47 72 71 -33-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
W1840.Parts.List
REF PART # DESCRIPTION
37 38 39 40 25 26 27 28 29 30 31 32 33 34 35 36 13 14 15 16 17 18 19 20 21 22 23 24 6 7 8 9 1 2 2-1 X1840002-1 FUSE 10A 250V 5 X 20MM GLASS 3 X1840003 TAP SCREW M3 X 5 4 5 X1840001 X1840002 X1840004 X1840005 LAMP CIRCUIT BOARD CIRCUIT BOARD E123995 CIRCUIT BOARD COVER PHLP HD SCR M4-.7 X 8 10 11 12 X1840006 X1840007 X1840008 X1840009 X1840010 X1840011 X1840012 R CAPACITOR 45M 250V 1-3/8 X 3 BASE STRAIN RELIEF MOUNTING PLATE PHLP HD SCR M5-.8 X 10 STRAIN RELIEF TYPE-1 10MM POWER CORD 14G 3W 72" 5-15P FLAT WASHER 12MM X1840013 X1840014 X1840015 X1840016 X1840017 X1840018 X1840019 X1840020 X1840021 X1840022 X1840023 X1840024 LED LIGHT PHLP HD SCR M5-.8 X 8 KNOB M5-.8 X 10 3-LOBE OUTER WHEEL COVER (L) HEX NUT M12-1.75
WHEEL FLANGE GRINDING WHEEL 8 X 5/8 X 1 AO60 PHLP HD SCR M5-.8 X 10 INNER WHEEL COVER (L) HEX BOLT M6-1 X 12 SPARK DEFLECTOR (L) HEX BOLT M5-.8 X 10 X1840025 X1840026 X1840027 X1840028 X1840029 X1840030 X1840031 X1840032 X1840033 X1840034 X1840035 X1840036 X1840037 X1840038 X1840039 X1840040 HEX NUT M4-.7
EYESHIELD (R) EYESHIELD (L) PHLP HD SCR M4-.7 X 8 FLAT WASHER 6MM KNOB M6-1 KNOB BOLT M6-1 X 14 3-LOBE TOOL REST (L) HEX BOLT M8-1.25 X 12 FLAT WASHER 8MM SUPPORT BRACKET (L) SPARK GUARD (R) MOTOR COVER (R) SET SCREW M5-.8 X 6 FEEDBACK WHEEL PHLP HD SCR M2.5-.45 X 6 X1840041 X1840042 X1840043 X1840044 X1840045 X1840046 X1840047 X1840048 X1840049 X1840050 X1840051 X1840052 X1840053 X1840054 X1840055 X1840056 X1840057 X1840058 X1840059 X1840060 X1840061 X1840062 X1840063 X1840064 X1840065 X1840066 X1840067 X1840068 X1840069 X1840070 X1840071 X1840072 X1840073 X1840074 X1840075 X1840076 X1840077 X1840078 X1840079 X1840080 X1840081
REF PART #
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 78 79 80 81 66 67 68 69 70 71 72 73 74 75 76 77
DESCRIPTION
RPM SENSOR GROMMET FLANGE NUT M5-.8
LOCK WASHER 6MM INNER MOTOR COVER (R) BALL BEARING 6203ZZ FLAT WASHER 5MM ROTOR STATOR WAVY WASHER 12MM MOTOR COVER (L) PHLP HD SCR M5-.8 X 160 HEX NUT M5-.8
EXT TOOTH WASHER 4MM PHLP HD SCR M4-.7 X 16 WIRE CLIP PLASTIC HEX BOLT M6-1 X 18 POTENTIOMETER B103 SWITCH MOUNTING PLATE TOGGLE SWITCH KEDU HY7 SPEED KNOB SPACER SPEED ADJ KNOB PHLP HD SCR M5-.8 X 16 PHLP HD SCR M4-.7 X 8 BASE PLATE RUBBER FOOT GRINDING WHEEL 8 X 5/8 X 1 AO36 HEX NUT M12-1.75
OUTER WHEEL COVER (R) TOOL REST (R) LOCK WASHER 5MM SUPPORT BRACKET (R) INNER WHEEL COVER (R) LED LENS LED COVER FLANGE NUT M4-.7
PHLP HD SCR M4-.7 X 10 L-BRACKET METAL HEX NUT M8-1.25
MACHINE ID LABEL TOUCH-UP PAINT, SHOP FOX WHITE -34-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Fold along dotted lIne Fold along dotted lIne
Woodstock international inc. p.o. box 2309 bellingham, Wa 98227-2309
place stamp Here tape along edges--please do not staple
WARRANTY WARRANTY
Woodstock International, Inc. warrants all Shop Fox machinery to be free of defects from workmanship and materials for a period of two years from the date of original purchase by the original owner. This warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence or accidents, lack of maintenance, or reimbursement of third party expenses incurred. Woodstock International, Inc. will repair, replace, or arrange for a dealer refund, at its expense and option, the Shop Fox machine or machine part proven to be defective for its designed and intended use, provided that the original owner returns the product prepaid to an authorized warranty or repair facility as designated by our Bellingham, Washington office with proof of their purchase of the product within two years, and provides Woodstock International, Inc. reasonable opportunity to verify the alleged defect through inspection. If it is determined there is no defect, or that the defect resulted from causes not within the scope of Woodstock International Inc.'s warranty, then the original owner must bear the cost of storing and returning the product. This is Woodstock International, Inc.’s sole written warranty and any and all warranties that may be implied by law, including any merchantability or fitness, for any particular purpose, are hereby limited to the duration of this written warranty. We do not warrant that Shop Fox machinery complies with the provisions of any law, acts or electrical codes. We do not reimburse for third party repairs. In no event shall Woodstock International, Inc.’s liability under this limited warranty exceed the purchase price paid for the product, and any legal actions brought against Woodstock International, Inc. shall be tried in the State of Washington, County of Whatcom. We shall in no event be liable for death, injuries to persons or property or for incidental, contingent, special or consequential damages arising from the use of our products.
Every effort has been made to ensure that all Shop Fox machinery meets high quality and durability standards. We are commited to continuously improving the quality of our products, and reserve the right to change specifications at any time.
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