Grizzly W1840 Variable Speed Grinder Owner Manual

Grizzly W1840 Variable Speed Grinder Owner Manual
MODEL W1839/W1840
6"/8" VARIABLE-SPEED GRINDER
OWNER'S MANUAL
(FOR MODELS MANUFACTURED SINCE 3/16)
Phone: (360) 734-3482 • Online Technical Support: techsupport@woodstockint.com
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 comprehension, 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 equipment, such as those dust masks that are specially designed to filter
out microscopic particles.
ELECTRICAL........................................ 11
Circuit Requirements........................... 11
Grounding Requirements....................... 12
Extension Cords................................. 12
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
OPERATIONS
OPERATIONS....................................... 19
Operation Overview............................ 19
Workpiece Inspection........................... 20
Wheel Selection................................. 20
Wheel Inspection................................ 21
Wheel Care....................................... 22
Wheel Dressing.................................. 23
Wheel Removal & Installation................. 24
SET UP
SETUP............................................... 13
Unpacking........................................ 13
Items Needed for Setup........................ 13
Inventory......................................... 14
Machine Placement............................. 15
Bench Mounting................................. 15
Assembly.......................................... 16
Test Run........................................... 18
MAINTENANCE..................................... 26
Schedule.......................................... 26
Grinding Wheels................................. 26
Cleaning & Protecting.......................... 26
Wheel Storage................................... 26
Wheel Dressing.................................. 26
ELECTRICAL
SAFETY................................................8
Standard Machinery Safety Instructions....... 8
Additional Safety for Benchtop Grinders.... 10
ACCESSORIES....................................... 25
Grinder Accessories............................. 25
SAFETY
INTRODUCTION......................................2
Contact Info........................................ 2
Manual Accuracy................................... 2
W1839 Machine Specifications.................. 3
W1840 Machine Specifications.................. 5
Components & Controls.......................... 7
INTRODUCTION
Contents
MAINTENANCE
SERVICE
PARTS
USE THE QUICK GUIDE PAGE LABELS TO SEARCH OUT INFORMATION FAST!
INTRODUCTION
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
INTRODUCTION
Contact Info
Manual Accuracy
We are committed to customer satisfaction. If
you have any questions or need help, use the
information below to contact us.
We are proud to provide a high-quality owner’s
manual with your new machine!
We made every effort to be exact with the
instructions, specifications, drawings, and photographs contained inside. Sometimes we make
mistakes, but our policy of continuous improvement also means that sometimes. the. machine.
you.receive.will.be.slightly.different.than.what.
is.shown.in.the.manual.
IMPORTANT:.Before.contacting,.please.get.the.
original. purchase. receipt,. serial. number,. and.
manufacture.date.of.your.machine..This.information. is. required. for. all. Technical. Support.
calls.and.it.will.help.us.help.you.faster..
Woodstock International Technical Support
Phone: (360) 734-3482
Email: techsupport@woodstockint.com
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.
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.
Technical Documentation Manager
P.O. Box 2309
Bellingham, WA 98227
Email: manuals@woodstockint.com
Alternatively, you can call our Technical Support
for help. Before calling, make sure you write
down the Manufacture.Date and Serial.Number
from the machine ID label (see below). Also, if
available, have a copy of your original.purchase.
receipt on hand. This information is required for
all Tech Support calls.
MODEL XXXX
MACHINE NAME
WARNING!
Specifications
Motor:
Specification:
Specification:
Specification:
Specification:
Weight:
Manufacture
Date
Date
Serial Number
Manufactured for Woodstock in Taiwan
-2-
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.
4. Only use this machine to collect wood dust/chips—never
use to collect glass, metal, liquids, asbestos, silica,
animal parts, biohazards, burning material/ashes, etc.
5. Always disconnect power before servicing or cleaning.
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
repair and protect cord from future damage.
10. Do not use without dust bag or filters in place.
11. Always wear a respirator when emptying bags.
12. Prevent unauthorized use by children or untrained users.
Serial Number
MODEL W1839
6" VARIABLE­SPEED GRINDER WITH WORK LIGHT
Product Dimensions
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-
INTRODUCTION
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
INTRODUCTION
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 W1840
8" VARIABLE­SPEED GRINDER WITH WORK LIGHT
Product Dimensions
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-
INTRODUCTION
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
INTRODUCTION
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-
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 Work Lamp: Work lamp turns ON/OFF
when machine is turned ON/OFF.
For Your Own Safety Read Instruction
Manual Before Operating Grinder
D. Wheel Guard: Prevents accidental contact
with grinding wheel, and contains sparks
during grinding.
a)
b)
c)
d)
e)
Replace cracked wheel immediately.
Always use guards and eye shields.
Do not overtighten wheel nut.
Only use flanges furnished with grinder.
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.
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.
A. Safety Shield: Helps protect operator
from sparks during grinding. Shield is not
a substitute for proper personal protective
equipment.
B.
E.
H. Tool Rest (Left): Provides a 60° "V" shaped
groove for sharpening drill bits. Also
includes a flat surface for general grinding.
Tilt angle is adjustable.
Spark Deflector: Helps contain sparks
inside wheel guard to reduce operator
exposure.
-7-
INTRODUCTION
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
SAFETY
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. measures—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.
Indicates.a.potentially.hazardous.situation.which,.if.not.avoided,.
MAY.result.in.minor.or.moderate.injury.
NOTICE
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.
Standard
Machinery Safety Instructions
Standard.Machinery.Safety.Instructions
OWNER’S.MANUAL..Read and understand this
owner’s manual BEFORE using machine.
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.
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!
DISCONNECT.POWER.FIRST..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
electrical components.
DANGEROUS.ENVIRONMENTS..Do not use
machinery in areas that are wet, cluttered,
or have poor lighting. Operating machinery
in these areas greatly increases the risk of
accidents and injury.
EYE.PROTECTION..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
glasses.
MENTAL.ALERTNESS.REQUIRED..Full mental
alertness is required for safe operation of
machinery. Never operate under the influence
of drugs or alcohol, when tired, or when
distracted.
-8-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
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.
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.
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.
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.
UNATTENDED.OPERATION..To reduce the risk
of accidental injury, turn machine OFF and
ensure all moving parts completely stop
before walking away. Never leave machine
running while unattended.
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!
MAINTAIN.WITH.CARE..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
or death.
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!
CHECK.DAMAGED.PARTS..Regularly inspect
machine for any condition that may affect
safe operation. Immediately repair or replace
damaged or mis-adjusted parts before
operating machine.
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..Keep children and
bystanders at a safe distance from the work
area. Stop using machine if they become a
distraction.
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.
GUARDS.&.COVERS..Guards and covers reduce
accidental contact with moving parts or flying
debris—make sure they are properly installed,
undamaged, and working correctly.
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-
SAFETY
WEARING.PROPER.APPAREL..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
of workpiece control.
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
SAFETY
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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
-11-
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.
ELECTRICAL
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 fullload 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.)
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.
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Grounding Requirements
ELECTRICAL
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 equipmentgrounding wire. If repair or replacement of the power
cord or plug is necessary, do not connect the equipmentgrounding 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.
120V
GROUNDED
5-15 RECEPTACLE
Grounding Prong
5-15 PLUG
Neutral Hot
Figure 2. NEMA 5-15 plug & receptacle.
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.
-12-
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.
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.
-13-
Wear safety glasses during
entire setup process!
SUFFOCATION HAZARD!
Immediately discard all
plastic bags and packing
materials to eliminate
choking/suffocation
hazards for children and
animals.
SETUP
Description
Qty
• Safety Glasses for Each Person...........................1
• Degreaser or Solvent for Cleaning........... As Needed
• Disposable Rags for Cleaning................. As Needed
• Mounting Hardware (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 operations before starting the
machine!
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.
SUFFOCATION HAZARD!
Immediately discard all
plastic bags and packing
materials to eliminate
choking/suffocation
hazards for children and
animals.
SETUP
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.
Box Contents (Figure 3):
Qty
A. 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. Safety Shield Mounting Plates............................2
J. Spark Deflectors............................................2
D
F
E
C
G
B
H
J
I
Figure 3. Tool rest and safety shield parts.
Hardware (Figure 4):
Qty
K. 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. Hex Bolts M8-1.25 x 12....................................4
Q. 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. Knobs M6-1..................................................2
V. Knob Bolts M6-1 x 18.......................................2
K
L
M
N
O
P
Q
R
S
T
U
V
Figure 4. Fastener inventory.
-14-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Machine Placement
Bench Mounting
Workbench Load
Number of Mounting Slots.........................2
Diameter of Mounting Hardware Needed... 3⁄8"
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.
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.
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.
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
Flat Washer
Machine Base
Workbench
Flat Washer
Lock Washer
Hex Nut
11”
12"
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.
15"
Figure 5. W1839 minimum working clearances.
Lag Screw
Flat Washer
12"
11”
Machine Base
Workbench
15 / "
1 2
Figure 8. Typical "Direct Mount" setup.
Figure 6. W1840 minimum working clearances.
-15-
SETUP
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.
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.
Safety Shield
Mounting Plate
Safety
Shield
Safety Shield
Mounting Bracket
Flange
Nuts
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.
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.
Figure 9. Safety shield components.
Safety
Shield
Assembly
Carriage
Bolt
SETUP
2.
Phillips
Head
Screws
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).
x2
Figure 11. Spark deflector attached.
4.
5.
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).
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.
Tool Rest
Tool Rest
Bracket
Lock
Washer
Knob
Bolt
Flat
Washer
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.
xx 44
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°.
⁄16"­­–1⁄8"
1
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.
SETUP
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.
Knob
Bolt
Figure 14. Tool rest gap.
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 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
operating grinder.
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.
⁄8"­­–1⁄4"
1
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.
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..
To test run machine, do these steps:
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 ON, verify motor operation, and slowly
rotate variable-speed dial to the right, then turn
machine OFF.
SETUP
1.
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.
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 does start, the switch
disabling feature is not functioning properly and the
switch must be replaced.
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:
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 1⁄16"—1⁄8" from grinding wheel,
and verifies/adjusts spark deflector and wheel gap is
between 1⁄8"—1⁄4".
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.
-19-
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. Above.all,.safety.
must.come.first!
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.
OPERATIONS
1.
To. reduce. the. risk. of. eye. injury. and.
long-term. respiratory. damage,. always.
wear. safety. glasses. and. a. respirator.
while.operating.this.machine.
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Workpiece Inspection
Wheel Selection
Some workpieces are not suitable for grinding
on a bench grinder. Before grinding, inspect all
workpieces for the following:
The Model W1839 only accepts Type-1 wheels
with a 1⁄2" bore. The W1840 only accepts Type-1
wheels with a 5⁄8" bore.
•
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 nonferrous 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 overheating and possibly bursting during use if
ignored. To restore a loaded grinding wheel
surface, redress with a dressing tool.
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 capabilities of various wheels. Always refer to the
manufacturer’s grinding recommendations when
selecting a wheel for your project.
OPERATIONS
•
•
•
The basic format for wheel numbering is:
Prefix
1
Abrasive
Grit Size
Type
A
60
Grade
Bond
Type
L
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.
Flexible/Unstable Workpiece: 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
avoided.
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.
Loose Parts: Make sure that the workpiece
is free of any parts like springs, pins, balls,
or other components that may loosen or dislodge during grinding, and hit the operator.
Grade is an indication of the hardness of the
wheel—“A” being the softest and “Z” being the
hardest.
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.
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.
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.
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.
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
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.
Grinding can be dangerous
Visually inspect this wheel
for cracks, nicks,chips
To perform ring test, do these steps:
Figure 17. Tapping locations when
performing a ring test.
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.
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!
-21-
OPERATIONS
Note: Finding exact spot to tap may take several
attempts.
Warped wheel flanges can increase
risk of grinding wheel breaking and
flying apart. Never use warped wheel
flanges. Always check flanges for flatness before installing grinding wheel.
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.
OPERATIONS
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.
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.
Refer to the instructions that accompany your dressing
accessory for complete details on how to properly dress
the wheel.
Grinder
Wheel
To dress grinder wheel, do these steps:
Wheel
Dresser
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 grinding surface appears across face of wheel.
Turn grinder OFF.
5.
Adjust spark deflector and tool rest as shown on
Page 17.
-23-
Figure 21. Example of dressing grinder
wheel.
OPERATIONS
4.
Tool
Rest
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.
Outer
Guard
Figure 18. Location of outer guard
hardware that must be removed when
removing wheel.
7.
Verify flatness of inner and outer flanges by placing
them on a flat surface. If either flange is warped or
damaged, replace it.
Mount new grinding wheel, as shown in Figure 20.
Tighten M16-2 hex nut snugly but do not overtighten. 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.
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
umi
Al
dB
o nd
-24-
V
it
— 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.
numn
e Type-1
M
Oxid
— If grinder runs smoothly, grinding wheel may now
be used.
M16-2 Hex Nut
P
6.
Paper
Disc
R
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.
0
5.
Outer Grinding
Wheel Flange
350
Remove outer grinding wheel flange and paper disc.
ie
4.
f
ri
OPERATIONS
Note: Nut on left side of grinder has left-hand
threads. Turn it clockwise to loosen.
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 sales@woodstockint.com.
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 D3744 STEELEX 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
81⁄2" long with a 33⁄4" long handle. The industrial diamond measures
0.25 carat.
-25-
OPERATIONS
The D4141 Drill Gauge Set offers 3 steel plates with clear markings,
precision stamped gauge holes and lists numbered (1 – 60), lettered
(A - Z) and fractional (1⁄16" – 1⁄2" by 1⁄64") sized drill bits. Stop guessing and check those drill sizes before you drill that hole! It even
includes a tap drill/clearance drill reference chart.
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 procedures! If this warning is ignored, serious 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
MAINTENANCE
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
1. Install switch disabling key.
Machine does not 1. Switch disabling key removed.
start or a breaker 2. Incorrect power supply voltage or circuit size. 2. Ensure correct power supply voltage and circuit
trips.
size.
3. Power supply circuit breaker tripped or fuse 3. Ensure circuit is sized correctly and free of shorts.
Reset circuit breaker or replace fuse.
blown.
4. Correct motor wiring connections.
4. Motor wires connected incorrectly.
5. Potentiometer/variable-speed dial controller 5. Test/replace.
at fault.
6. Inspect/replace.
6. Circuit board at fault.
7. Test/repair/replace.
7. Motor at fault.
Machine stalls or 1. Machine undersized for task.
is underpowered.
2.
3.
4.
5.
Machine has
vibration or
noisy operation.
1. Use new grinding wheel; reduce feed rate/pressure.
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.
Motor wired incorrectly.
Motor overheated.
Run capacitor at fault.
Motor bearings at fault.
1. Machine incorrectly mounted to workbench or 1. Adjust feet, shim, or tighten mounting hardware.
floor.
2. Motor or component loose.
2. Inspect/replace damaged bolts/nuts, and re-tighten with thread-locking fluid.
3. Grinding wheel at fault/arbor hole not round. 3. Dress/replace grinding wheel (Page 23).
4. Test by rotating shaft; rotational grinding/loose
4. Motor bearings at fault.
shaft requires bearing replacement.
5. Test with dial indicator and replace motor.
5. Motor shaft bent.
SERVICE
-27-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Operation
PROBLEM
POSSIBLE CAUSE
CORRECTIVE ACTION
Machine slows
when operating.
1. Operator applying too much pressure too 1. Slow down rate of movement of workpiece into
wheel; use less pressure.
quickly.
2. Adjust RPM.
2. RPM too low.
Wavy condition
on surface of
workpiece.
1. Machine vibrating.
1. Ensure machine is securely mounted to a solid surface (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.
2. Workpiece not being held firmly.
3. Wheel face uneven.
4. Wheel is too hard.
Lines on surface 1. Impurity on wheel surface.
of workpiece.
2. Workpiece not being held tightly.
1. Dress grinding wheel (Page 23).
2. Use a holding device to firmly retain workpiece.
Burning spots
or cracks in the
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. Improper type of grinding wheel.
2. Improper feed rate.
3. Workpiece requires quenching.
1. Operator applying too much pressure too 1. Slow down rate of movement of workpiece into
wheel; use less pressure.
quickly.
2. Wheel too soft for material being ground, select
2. Wheel is too soft.
harder bond.
3. Replace grinding wheel (Page 24).
3. Wheel diameter too small.
4. Re-dress grinding wheel (Page 23).
4. Bad wheel dress.
5. Replace grinding wheel. Consult manufacturer of
5. Defective wheel bonding.
grinding wheel.
SERVICE
Wheel dulls
quickly, grit
falls off.
-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!
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.
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.
CAPACITORS/INVERTERS. 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
capacitors.
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..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
completing the task.
CIRCUIT.REQUIREMENTS. You MUST follow
the requirements at the beginning of this
manual when connecting your machine to a
power source.
EXPERIENCING.DIFFICULTIES. If you are
experiencing difficulties understanding
the information included in this section,
contact our Technical Support at
(360) 734-3482.
The photos and diagrams
included in this section are
best viewed in color. You
can view these pages in
color at www.shopfox.biz.
BLUE
WHITE
BROWN
GREEN
GRAY
YELLOW
YELLOW
GREEN
PURPLE
RED
ORANGE
PINK
-29-
LIGHT
BLUE
BLUE
WHITE
TURQUOISE
SERVICE
WIRING DIAGRAM COLOR KEY
BLACK
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Wiring Diagram
120 Volt Motor
Ground
Ground
Rotation
Sensor
Wt
Wt
Wt
Run
Capacitor
45MFD
250VAC
Safety Switch
KEDU HY7
Speed Control
Potentiometer
B103
Wt
Wt
B103
Switch Panel
(Viewed from Back)
Wt
Read
Page 29
STOP
Before
Wiring
E123995
Wt
T10AL/250V
Wt
Wt
T4/L
F1 T2/M
U6
R27
T1/M
T2/N
Grinder Base
(Viewed from Bottom)
Circuit Board Box
(Viewed from Top)
Wt
SERVICE
Hot
Neutral
Ground
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.
Wt
120 VAC
5-15 Plug
(Pre-Wired)
-30-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
PARTS
W1839 Main Breakdown
30
36 22
24
77
76
29
44
47
26
40
75
43
45
20
37 73
38 53
39
18
31
49
46
11
5
10
9
22
23
24
20
25
17 18
71
47
33
32
29
58
59
14
60
61
63
62
64
65
28
15
70
56
6
57
2
5
4
3
2-1
1
18
55
8
81
21
27
47 71 19
16
7
78
79
44
33
72
80
42
54
52
30
29
34
48
51 50
77
76
47
41
13
29
71
18
42
46
12
15
68
67
71
74
69
66
63
31
34
35
PARTS
-31-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
W1839 Parts List
REF PART #
DESCRIPTION
REF PART #
DESCRIPTION
1
2
2-1
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
LAMP CIRCUIT BOARD
CIRCUIT BOARD E123995
FUSE 10A 250V 5 X 20MM GLASS
TAP SCREW M3 X 5
CIRCUIT BOARD COVER
PHLP HD SCR M4-.7 X 8 W/CAPTIVE WASHER
R CAPACITOR 30M 300V 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
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
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
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
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
PARTS
X1839001
X1839002
X1839002-1
X1839003
X1839004
X1839005
X1839006
X1839007
X1839008
X1839009
X1839010
X1839011
X1839012
X1839013
X1839014
X1839015
X1839016
X1839017
X1839018
X1839019
X1839020
X1839021
X1839022
X1839023
X1839024
X1839025
X1839026
X1839027
X1839028
X1839029
X1839030
X1839031
X1839032
X1839033
X1839034
X1839035
X1839036
X1839037
X1839038
X1839039
X1839040
-32-
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
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
W1840 Main Breakdown
36
24
77
76
30
44
22
47
73
20
45
74
38
39
53
43
42
41
46
46
51 50
54
11
22
16
47 71
18
17
55
10
9
30
19 18
5
81
7
58
20
3
33
2-1
63
25
28
47
32
62
2
1
31
60
61
57
4
47
14
44
5
29
59
6
15
71
56
8
78
79
21
27
80
42
47
70
48
49
52
24
23
29
31
12
72
34
33
13
77
76
47
37
40
75
44
71
18
71
26
29
68
18
67
29
15
69
65
66
64
47
34
35
PARTS
-33-
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
W1840 Parts List
REF PART #
DESCRIPTION
REF PART #
DESCRIPTION
1
2
2-1
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
LAMP CIRCUIT BOARD
CIRCUIT BOARD E123995
FUSE 10A 250V 5 X 20MM GLASS
TAP SCREW M3 X 5
CIRCUIT BOARD COVER
PHLP HD SCR M4-.7 X 8
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
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
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
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
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
PARTS
X1840001
X1840002
X1840002-1
X1840003
X1840004
X1840005
X1840006
X1840007
X1840008
X1840009
X1840010
X1840011
X1840012
X1840013
X1840014
X1840015
X1840016
X1840017
X1840018
X1840019
X1840020
X1840021
X1840022
X1840023
X1840024
X1840025
X1840026
X1840027
X1840028
X1840029
X1840030
X1840031
X1840032
X1840033
X1840034
X1840035
X1840036
X1840037
X1840038
X1840039
X1840040
-34-
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
Model W1839 & W1840 (For Machines Mfd. Since 3/16)
Fold along dotted lIne
place
stamp
Here
Woodstock international inc.
p.o. box 2309
bellingham, Wa 98227-2309
Fold along dotted lIne
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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